Aluminum conductor composite core reinforced cable and method of manufacture

ABSTRACT

This invention relates to an aluminum conductor composite core reinforced cable (ACCC) and method of manufacture. An ACCC cable has a composite core surrounded by at least one layer of aluminum conductor. The composite core comprises a plurality of fibers from at least one fiber type in one or more matrix materials. The composite core can have a maximum operating temperature capability above 100° C. or within the range of about 45° C. to about 230° C., at least 50% fiber to resin volume fraction, a tensile strength in the range of about 160 Ksi to about 370 Ksi, a modulus of elasticity in the range of about 7 Msi to about 37 Msi and a coefficient of thermal expansion in the range of about −0.7×10 −6  m/m/° C. to about 6×10 −6  m/m/° C. According to the invention, a B-stage forming process may be used to form the composite core at improved speeds over pultrusion processes wherein the speeds ranges from about 9 ft/min to about 60 ft/min.

CROSS REFERENCES TO RELATED APPLICATIONS

[0001] In relation to this Continuation in Part Application, applicantsclaim priority of earlier PCT filing PCT/US03/12520 filed in theInternational Receiving Office of the United States Patent and TrademarkOffice on 23 Apr. 2003, the entire disclosure of which is incorporatedby reference herein, which claims priority from U.S. provisionalapplication Serial No. 60/374,879 filed in the United States Patent andTrademark Office on 23 Apr. 2002, the entire disclosure of which isincorporated by reference herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

REFERENCE TO A “MICROFICHE APPENDIX”

[0003] Not Applicable

BACKGROUND OF THE INVENTION

[0004] 1. Field of the Invention

[0005] The present invention relates to an aluminum conductor compositecore (ACCC) reinforced cable and method of manufacture. Moreparticularly, the present invention relates to a cable for providingelectrical power having a composite core, formed by fiber reinforcementsand a matrix, surrounded by aluminum conductor capable of carryingincreased ampacity and operating at elevated temperatures.

[0006] 2. Description of the Related Art

[0007] In a traditional aluminum conductor steel reinforced cable (ACSR)the aluminum conductor transmits the power and the steel core isdesigned to carry the transfer load. Conductor cables are constrained bythe inherent physical characteristics of the components; thesecomponents limit ampacity. Ampacity is a measure of the ability to sendpower through the cable. Increased current or power on the cable causesa corresponding increase in the conductor's operating temperature.Excessive heat will cause the cable to sag below permissible levels.Typical ACSR cables can be operated at temperatures up to 100° C. on acontinuous basis without any significant change in the conductor'sphysical properties related to sag. Above 100° C., ACSR cables sufferfrom thermal expansion and a reduction in tensile strength. Thesephysical changes create excessive line sage. Such line sag has beenidentified as one of the possible causes of the power blackout in theNortheastern United States in 2003. The temperature limits constrain theelectrical load rating of a typical 230-kV line, strung with 795 kcmilACSR “Drake” conductor, to about 400 MVA, corresponding to a current of1000 A. Therefore, to increase the load carrying capacity oftransmission cables, the cable itself must be designed using componentshaving inherent properties that allow for increased ampacity withoutinducing excessive line sag.

[0008] Although ampacity gains can be obtained by increasing theconductor area that surrounds the steel core of the transmission cable,increasing conductor volume increases the weight of the cable andcontributes to sag. Moreover, the increased weight requires the cable touse increased tension in the cable support infrastructure. Such largeweight increases typically would require structural reinforcement orreplacement of the electrical transmission towers and utility poles.Such infrastructure modifications are typically not financiallyfeasible. Thus, there is financial motivation to increase the loadcapacity on electrical transmission cables while using the existingtransmission structures and liens.

[0009] Prior art applications disclose a composite core comprised of asingle type of glass fiber and thermoplastic resin. The object is toprovide an electrical transmission cable which utilizes a reinforcedplastic composite core as a load bearing element in the cable and toprovide a method of carrying electrical current through an electricaltransmission cable which utilizes an inner reinforced plastic core. Thecomposite core fails in these objectives. A one fiber system comprisingglass fiber does not have the required stiffness to attract transferload and keep the cable from sagging. Secondly, a composite corecomprising glass fiber and thermoplastic resin does not meet theoperating temperatures required for increased ampacity, namely, between90° C. and 230° C.

[0010] Physical properties of composite cores are further limited byprocessing methods. Previous processing methods cannot achieve a highfiber to resin ratio by volume or weight. These processes do not allowfor creation of a fiber rich core that will achieve the strengthrequired for electrical cables. Moreover, the processing speed ofprevious processing methods is limited by inherent characteristics ofthe process itself. For example, traditional pultrusion dies areapproximately 36 inches long, having a constant cross section. Thelonger dies create increased friction between the composite and the dieslowing processing time. The processing times in such systems for epoxyresins range from about 3 inches/minute to about 12 inches/minute.Processing speeds using polyester and vinyl ester resins can producecomposites at up to 72 inches/minute. With thousands of miles of cablesneeded, these slow processing speeds fail to meet the need in afinancially acceptable manner.

[0011] It is therefore desirable to design an economically feasiblecable that facilitates increased ampacity without corresponding cablesag. It is further desirable to process composite cores using a processthat allows configuration and tuning of the composite cores duringprocessing and allows for processing at speeds up to 60 ft/min.

BRIEF SUMMARY OF THE INVENTION

[0012] An aluminum conductor composite core (ACCC) reinforced cable canameliorate the problems in the prior art. The ACCC cable is anelectrical cable with a composite core made from one or more fiber typereinforcements and embedded in a matrix. The composite core is wrappedin an electrical conductor. An ACCC reinforced cable is ahigh-temperature, low-sag conductor, which can be operated attemperatures above 100° C. while exhibiting stable tensile strength andcreep elongation properties. In exemplary embodiments, the ACCC cablecan operate at temperatures above 100° C. and in some embodiments up toor near 230° C. An ACCC cable with a similar outside diameter mayincrease the line rating over a prior art cable by at least 50% withoutany significant changes in the weight of the conductor.

[0013] In an ACCC cable, the core of the distribution and transmissioncable is replaced with a composite strength member comprising aplurality of fibers selected from one or more fiber types and embeddedin a matrix. The important characteristics of the ACCC cable are arelatively high modulus of elasticity and a relatively low coefficientof thermal expansion, which help increase the ampacity of the conductorcable. It is further desirable to design composite cores having longterm durability. The composite strength member may operate at leastsixty years, and more preferably seventy years, at elevated operatingtemperatures above 90° C. and possibly up to 230° C.

[0014] Further, the invention allows for formation of a composite corehaving a smaller core size. The smaller core size acts as the only loadbearing member in the ACCC cable. This smaller core size allows thecable to accommodate an increased volume of aluminum without changingthe conductor outside diameter. The ACCC cable can have the same orgreater strength and the same or less weight as a conductor cable with asteel core, but can include more conductor around the core. With moreconductor, the ACCC cable can carry increased ampacity.

[0015] To achieve the desired ampacity gains, a composite core accordingto the invention may combine fibers having a low modulus of elasticityfor lower stiffness with fibers having a high modulus of elasticity forincreased stiffness or strength. By combining fibers, new property setsare obtained, including different modulus of elasticity, thermalexpansion, density, and cost. Sag versus temperature calculations showimproved ampacity over ACSR cables when a high-strength andhigh-stiffness composite is combined with a lower strength and lowerstiffness composite.

[0016] Composite cores according to the invention meet certain physicalcharacteristics dependent upon the selection of fiber types and matrixmaterial. Composite cores according to the invention have substantiallylow coefficient of thermal expansions, substantially high tensilestrength, and ability to withstand substantially high operatingtemperatures, ability to withstand low ambient temperatures,substantially high dielectric properties, and sufficient flexibility topermit winding on a transportation wheel or a transportation drum. Inparticular, composite cores according to the present invention may have:a tensile strength above 160 Ksi, and more preferably within the rangeof about 160 Ksi to about 380 Ksi; a modulus of elasticity above 7 Msi,and more preferably within the range of about 7 Msi to about 37 Msi; anoperating temperature capability above 45° C., and more preferablywithin the range of about 90° C. to about 230° C.; and, a coefficient ofthermal expansion below 6×10⁻⁶ m/m/° C., and more preferably within therange of about −0.7×10⁻⁴ m/m/° C. to about 6×10⁻⁴ m/m/° C. These rangesmay be achieved by a single fiber type or by a combination of fibertypes. Practically, most cores within the scope of this inventioncomprise two or more fiber types, but a single fiber type may be able toachieve the above ranges. In addition, depending on the physicalcharacteristics desired in the final composite core, the composite corecan accommodate variations in the relative amounts of fibers, fibertypes, or matrix type.

[0017] Composite cores of the present invention can be formed by aB-stage forming process wherein fibers are wetted with resin andcontinuously pulled through a plurality of zones within the process. TheB-stage forming process relates generally to the manufacture ofcomposite core members and relates specifically to an improved apparatusand process for making resin impregnated fiber composite core members.More specifically, according to an exemplary embodiment, a multi-phaseB-stage process forms, from fiber and resin, a composite core memberwith superior strength, higher ampacity, lower electrical resistance andlighter weight. The process enables formation of composite core membershaving a fiber to resin ratio that maximizes the flexural strength, thecompressive strength, and the tensile strength. In a further embodiment,the composite core member is wrapped with high conductivity aluminum orother conductor resulting in an ACCC cable having high strength and highstiffness characteristics.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0018] These and other features of the invention are best understood byreferring to the detailed description of the invention, read in light ofthe accompanying drawings, in which:

[0019]FIG. 1 is a schematic diagram of a B-stage forming process usedfor forming fiber composite core members in accordance with the presentinvention.

[0020]FIG. 2 is a schematic diagram of a bushing showing sufficientlyspaced passageways for insertion of the fibers in a predeterminedpattern to guide the fibers through the B-stage forming process inaccordance with the present invention.

[0021]FIG. 3 is a schematic view of the structure of a bushing; saidview showing the passageways used to shape and compacts the bundles offibers in accordance with the present invention.

[0022]FIG. 4 is schematic comparison of two different bushings showing areduction in the passageways from one bushing to the next to shape andcompact the fibers into bundles in forming the composite core inaccordance with the present invention.

[0023]FIG. 5 shows a cross-sectional view of thirty possible compositecore cross-section geometries according to the invention.

[0024]FIG. 6 is a multi-dimensional cross-sectional view of a pluralityof bushings overlaid on top of one another showing the decreasingpassageway size with respective bushings.

[0025]FIG. 7 is a multi-phase schematic view of a plurality of bushingsshowing migration of the passageways and diminishing size of thepassageways with each succesive bushing in accordance with theinvention.

[0026]FIG. 8 is a cross sectional view of one embodiment of a compositecore according to the invention.

[0027]FIG. 9 is a schematic view of an oven process having crosscircular air flow to keep the air temperature constant in accordancewith the invention.

[0028]FIG. 10 is a cross-sectional view of the heating element in theoven represented in FIG. 9 showing each heater in the heating element inaccordance with the invention.

[0029]FIG. 11 is a schematic view of one embodiment of an aluminumconductor composite core (ACCC) reinforced cable showing an innercomposite core and an outer composite core surrounded by two layers ofaluminum conductor according to the invention.

[0030] To clarify, each drawing includes reference numerals. Thesereference numerals follow a common nomenclature. The reference numeralwill have three digits. The first digit represents the drawing numberwhere the reference numeral was first used. For example, a referencenumeral used first in drawing one will have a numeral like 1XX, while anumeral first used in drawing four will have a numeral like 4XX. Thesecond two numbers represent a specific item within a drawing. One itemin FIG. 1 may be 101 while another item may be 102. Like referencenumerals used in later drawing represent the same item. For example,reference numeral 102 in FIG. 3 is the same item as shown in FIG. 1. Inaddition, the drawings are not necessarily drawn to scale but areconfigured to clearly illustrate the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0031] The present invention will now be described more fullyhereinafter with reference to the accompanying drawings, in whichexemplary embodiments of the invention are shown. This invention may,however, be embodied in many different forms and should not be construedas limited to the embodiments set forth herein; rather, theseembodiments are provided so that the disclosure will fully convey thescope of the invention to those skilled in the art.

[0032] An ACCC Reinforced Cable

[0033] The present invention relates to a reinforced composite coremember made from a plurality of fiber reinforcements from one or morefiber types embedded in a matrix. A further embodiment of the inventionuses the composite core in an aluminum conductor composite corereinforced (ACCC) cable. These ACCC cables can provide for electricalpower distribution wherein electrical power distribution includesdistribution and transmission cables. FIG. 11 illustrates an embodimentof an ACCC reinforced cable 300. This one embodiment in FIG. 11illustrates an ACCC reinforced cable having a carbon fiber reinforcementand epoxy resin composite inner core 302 and a glass fiber reinforcementand epoxy resin composite outer core 304, surrounded by a first layer ofaluminum conductor 306 wherein a plurality of trapezoidal shapedaluminum strands helically surround around the composite core and havinga second layer of aluminum conductor 308 wherein a plurality oftrapezoidal shaped aluminum strands helically surround around the firstaluminum layer 306.

[0034] Composite cores of the present invention can comprise thefollowing characteristics: at least one type of fiber, variable relativeamounts of each fiber type, fiber types of substantially small diameter,fiber types of a substantially continuous length, composite cores havinga high packing density, fiber tows having relative spacing within thepacking density, a fiber to resin volume fraction 60% or lower, a fiberto resin weight fraction 72% or lower by weight, adjustable volumefraction, substantially low coefficient of thermal expansion, asubstantially high tensile strength, ability to withstand asubstantially high range of operating temperatures, ability to withstandsubstantially low ambient temperatures, having the potential tocustomize composite core resin properties, substantially high dielectricproperties, having the potential of a plurality of geometric crosssection configurations, and sufficient flexibility to permit winding ofcontinuous lengths of composite core.

[0035] A composite core of the following invention can have a tensilestrength above 160 Ksi, and more preferably within the range of about160 Ksi to about 380 Ksi; a modulus of elasticity above 7 Msi, and morepreferably within the range of about 7 Msi to about 37 Msi; an operatingtemperature capability above 45° C., and more preferably within therange of about 45° C. to about 230° C.; and, a coefficient of thermalexpansion below 6×10⁻⁶ m/m/° C, and more preferably within the range ofabout −0.7×10⁻⁶ m/m/° C. to about 6×10⁻⁶ m/m/° C.

[0036] To achieve a composite core in the above stated ranges, differentmatrix materials and fiber types may be used. The matrix and the fiberproperties are explained further below. First, matrix materials embedthe fibers. In other words, the matrix bundles and holds the fiberstogether as a unit—a load member. The matrix assists the fibers to actas a single unit to withstand the physical forces on the ACCC cable. Thematrix material may be any type of inorganic or organic material thatcan embed and bundle the fibers into a composite core. The matrix caninclude, but is not limit to, materials such as glue, ceramics, metalmatrices, resins, epoxies, foams, elastomers, or polymers. One skilledin the art will recognize other materials that may be used as matrixmaterials.

[0037] While other materials may be used, an exemplary embodiment of theinvention uses epoxy resins. Throughout the remainder of the inventionthe term resin or epoxy may be used to identify the matrix. However, theuse of the terms epoxy and resin are not meant to limit the invention tothose embodiments, but all other types of matrix material are includedin the invention. The composite core of the present invention maycomprise resins having physical properties that are adjustable toachieve the objects of the present invention. The present invention mayuse any suitable resin. Suitable resins may include thermosettingresins, thermoplastic resins or thermoplastically modified resins,toughened resins, elastomerically modified resins, multifunctionalresins, rubber modified resins, Cyanate Esters, or Polycyanate resins.Some thermosetting and thermoplastic resins may include, but are notlimited to, phenolics, epoxies, polyesters, high-temperature polymers(polyimides), nylons, fluoropolymers, polyethelenes, vinyl esters, andthe like. One skilled in the art will recognize other resins that may beused in the present invention.

[0038] Depending on the intended cable application, suitable resins areselected as a function of the desired cable properties to enable thecomposite core to have long term durability at high temperatureoperation. Suitable resins may also be selected according to the processfor formation of the composite core to minimize friction duringprocessing, to increase processing speed, and to achieve the appropriatefiber to resin ratio in the final composite core.

[0039] The composite core of the present invention comprises resinshaving good mechanical properties and chemical resistance. These resinsmay be able to function with prolonged environmental exposure for atleast about 60 years of usage. More preferably, the composite core ofthe present invention can comprise resins having good mechanicalproperties and chemical resistance at prolonged exposure for at leastabout 70 years of usage. Further, the composite core of the presentinvention comprises resins that may operate anywhere above 45° C. andpossibly up to 230° C. More preferably, the resin can operate wellaround 180° C. or above.

[0040] An embodiment of an epoxy system may include a low viscositymultifunctional epoxy resin using an anhydride hardener and an imidazolaccelerator. An example of this type of epoxy system may be theAraldite® MY 721/Hardener 99-023/Accelerator DY 070 hot curing epoxymatrix system by Vantico Inc. and specified in the like titled datasheet dated September 2002. The resin has a chemical description ofN,N,N′,N′-Tetraglycidyl4,4′-methylenebisbenzenamine. The hardener isdescribed as 1 H-Imidazole, 1-methyl-1-Methylimidazole. This exemplaryresin epoxy system can have the following properties: a tensileelongation around 1.0% to 1.5%; a flexural strength around 16.5 Kpsi to19.5 Kpsi; a tensile strength around 6.0 Kpsi to 7.0 Kpsi; a tensilemodulus around 450 Kpsi to 500 Kpsi; a flexural elongation around 4.5%to 6.0%. Another embodiment of an epoxy resin system may be amultifunctional epoxy with a cycloaliphatic-amine blend hardener. Anexample of this type of epoxy system may be the JEFFCO 1401-16/4101-17epoxy system for infusion by JEFFCO Products Inc. and specified in thelike titled data sheet dated July 2002. This exemplary resin epoxysystem can have the following properties: a Shore D Hardness around 88D;an ultimate tensile strength of 9,700 pounds; an elongation at tensilestrength around 4.5% to 5.0%; an ultimate elongation around 7.5% to8.5%; a flexural strength around 15.25 Kpsi; and an ultimate compressivestrength around 14.5 Kpsi. These embodiments of the epoxy resin systemare exemplary and are not meant to limit the invention to theseparticular epoxy resin systems. One skilled in the art will recognizeother epoxy systems that will produce composite cores within the scopeof this invention.

[0041] The composite core of the present invention can comprise a resinthat is tough enough to withstand splicing operations without allowingthe composite body to crack. The composite core of the present inventioncan comprise resins having a neat resin fracture toughness above 0.87INS-lb/in and possible up to about 1.24 INS-lb/in.

[0042] The composite core of the present invention can comprise a resinhaving a low coefficient of thermal expansion. A low coefficient ofthermal expansion reduces the amount of sag in the resulting cable. Aresin of the present invention may have a coefficient of thermalexpansion below about 4.2×10⁻⁵ m/m/° C. and possibly lower than 1.5×10⁻⁵m/m/° C. The composite core of the present invention can comprise aresin having an elongation greater than about 2.1% or more preferablygreater than 4.5%.

[0043] Second, the composite core comprises a plurality of fiberreinforcements from one or more fiber types. Fiber types may be selectedfrom: carbon (graphite) fibers—both HM and HS (pitch based), Kevlarfibers, basalt fibers, glass fibers, Aramid fibers, boron fibers, liquidcrystal fibers, high performance polyethylene fibers, or carbonnanofibers or nanotubes. Several types of carbon, boron, Kevlar andglass fibers are commercially available. Each fiber type may havesubtypes that can be variously combined to achieve a composite withcertain characteristics. For instance, carbon fibers may be any typefrom the Zoltek Panex®, Zoltek Pyron®, Hexcel, or Thornel families ofproducts. These carbon fibers may come from a PAN Carbon Fiber or aPolyacrylonitrile (PAN) Precursor. There are hundreds of different typesof carbon fibers, and one skilled in the art would recognize thenumerous carbon fibers that may be used in the present invention. Thereare also numerous different types of glass fibers. For instance, anA-Glass, B-Glass, C-Glass, D-Glass, E-Glass, S-Glass, AR-Glass, orR-Glass may be used in the present invention. Fiberglass and paraglassmay also be used. As with carbon fibers, there are hundreds of differenttypes of glass fibers, and one skilled in the art would recognize thenumerous glass fibers that may be used in the present invention. It isnoted that these are only examples of fibers that may meet the specifiedcharacteristics of the invention, such that the invention is not limitedto these fibers only. Other fibers meeting the required physicalcharacteristics of the invention may be used. One skilled in the artwill recognize other fibers that may be used in the present invention.In addition, examples of cores using carbon and glass fibers will beexplained. These descriptions are not meant to limit the invention tothose fiber types. Rather, one skilled in the art will recognize fromthe description that other fibers may be used in the invention, andthose different fibers may have similar or different propertiesdepending on the desired composite core.

[0044] To achieve these physical characteristics, composite cores inaccordance with the present invention may comprise only one type offiber. The composite core may be a uniform section or layer that isformed from one fiber type and one matrix type. For instance, thecomposite core may be a carbon fiber embedded in resin. The core mayalso be a glass fiber embedded in a polymer, and the core may also bebasalt embedded in a vinyl ester. However, most cables, within the scopeof this invention, may comprise at least two distinct fiber types.

[0045] The two fiber types may be general fiber types, fiber classes,fiber type subtypes, or fiber type genera. For instance, the compositecore may be formed using carbon and glass. Yet, when an embodimentmentions two or more fiber types, the fiber types need not be differentclasses of fibers, like carbon and glass. Rather, the two fiber typesmay be within one fiber class or fiber family. For instance, the coremay be formed from E-glass and S-glass, which are two fiber types orfiber subtypes within the glass fiber family or fiber class. In anotherembodiment, the composite may comprise two types of carbon fibers. Forinstance, the composite may be formed from IM6 carbon fiber and IM7carbon fiber. One skilled in the art will recognize other embodimentsthat would use two or more types of fibers.

[0046] The combination of two or more fiber types into the compositecore member offers substantial improvements in strength to weight ratioover materials, such as steel, commonly used for cables in an electricalpower transmission and distribution system. Combining fiber types alsomay allow the composite core to have sufficient stiffness and strengthbut maintain some flexibility.

[0047] Composite cores of the present invention may comprise fiber towshaving relatively high yield or small K numbers. A fiber tow is a bundleof continuous microfibers, wherein the composition of the tow isindicated by its yield or K number. For example, a 12K carbon tow has12,000 individual microfibers, and a 900 yield glass tow has 900 yardsof length for every one pound of weight. Ideally, microfibers wet outwith resin such that the resin coats the circumference of eachmicrofiber within the bundle or tow. Wetting may be affected by towsize, the number of microfibers in the bundle, and also by individualmicrofiber size. Larger tows are more difficult to wet around individualfibers in the bundle due to the number of fibers contained within thebundle. Smaller fiber diameter increases the distribution of resinaround each fiber within each fiber tow. Wetting and infiltration of thefiber tows in composite materials is of critical importance to theperformance of the resulting composite. Incomplete wetting results inflaws or dry spots within the fiber composite that reduce strength anddurability of the composite product. Fiber tows may also be selected inaccordance with the size of fiber tow that the process can handle.

[0048] One process for forming composite cores in accordance with thepresent invention is called the B-stage forming process. Fiber tows ofthe present invention for carbon may be selected from 2K and up, butmore preferably from about 4K to about 50K. Glass fiber tows may be 50yield and up, but more preferably from about 115 yield to about 1200yield.

[0049] For glass fibers, individual fiber size diameters in accordancewith the present invention may be below 15 μm, or more preferably withinthe range of about 8 μm to about 15 μm, and most preferably about 10 μmin diameter. Carbon fiber diameters may be below 10 μm, or morepreferably within the range of about 5 μm to about 10 μm, and mostpreferably about 7 μm. For other types of fibers, a suitable size rangeis determined in accordance with the desired physical properties. Theranges are selected based on optimal wet-out characteristics andfeasibility of use. For example, fibers less than about 5 μm are sosmall in diameter that they pose certain health risks to those thathandle the fibers. In contrast, fibers approaching 25 μm in diameter aredifficult to work with because they are stiffer and more brittle.

[0050] Composite cores of the present invention may comprise fiber towsthat are substantially continuous in length. In practice, carbon fibertows comprising the present invention may be between about 1000 and 3000meters in length, depending on the size of the fiber spool. However,glass fiber lengths can be up to 36 km in length. It is most preferableto select the longest fibers that the processing equipment willaccommodate due to less splicing of fibers to form a continuouscomposite core. When the material on a fiber tow spool ends, fiber endsmay be glued or mechanically connected end-to-end forming asubstantially continuous fiber tow length.

[0051] Composite cores of the present invention may comprise fibershaving a high packing efficiency relative to prior art cores, such assteel, for conductor cables. Traditional steel conductor cablesgenerally comprise several round steel wires. Due to the round shape ofthe wires, the wires cannot pack tightly together and can only achieve amaximum packing efficiency of about 74%. The only way that a steel corecould have 100% packing efficiency would be to have a solid steel rod asopposed to several round steel wires. Using a solid steel rod is notpossible because the final cable would be inflexible. The steel rodwould bend slightly to the point of yield, which may only be a fewinches. However, if the rod is bent past the point of yield, it willremain bent and not return to its original shape. In the presentinvention, individual fibers can be oriented, coated with resin, andcured to form a composite core member having 100% packing efficiency.Higher packing efficiency yields a composite core with strength that isgreater for a given volume than a steel core. In addition, higherpacking efficiency allows for formation of a composite core with asmaller diameter. The smaller diameter core can allow an increasedamount of aluminum conductor material to be wrapped around the compositecore without changing the outside diameter of the conductor.

[0052] Composite cores of the present invention can comprise fiber typesthat are substantially heat resistant. Higher operating temperaturesoccur when higher amperage is sent through a conductor during increaseddemand periods. Heat resistant fiber types enable an ACCC cable tooperate at higher operating temperatures. An ACCC cable may transmit thehigher amperages that can cause the higher conductor temperatures. Thefiber types in the present invention may withstand operatingtemperatures above 45° C. and may possibly withstand temperatures ashigh as 230° C. More preferably, the fibers in the present inventionhave the ability to withstand operating temperatures above 100° C., andmost preferably, withstand temperatures around 180° C. or above.Moreover, fiber types in the present invention can withstand an ambienttemperature above 45° C. and more preferably within the range betweenabout 45° C. to about 90° C. That is, under no load conditions, thecomposite core may be able to withstand temperatures as low as about 45°C. without suffering impairment of the core's physical characteristics.

[0053] A relative amount of each type of fiber can vary depending on thedesired physical characteristics of the composite core. For example,fibers having a higher modulus of elasticity enable formation of a highstrength and high-stiffness composite core. As an example, carbon fibershave a modulus of elasticity from 15 Msi and up, but more preferably,from about 22 Msi to about 37 Msi; glass fibers are considered lowmodulus fibers having a modulus of elasticity from 3 Msi and up, butmore preferably, from about 6 Msi to about 7 Msi. As one skilled in theart will recognize, other fibers may be chosen that can achieve thedesired physical properties for the composite core.

[0054] Composite cores of the present invention can comprise fibershaving relatively high tensile strengths. The degree of sag in anoverhead voltage power transmission cable varies as the square of thespan length and inversely with the tensile strength of the cable. Anincrease in the tensile strength can effectively reduce sag in an ACCCcable. As an example, carbon or graphite fibers may be selected having atensile strength above 350 Ksi and more preferably within the range ofabout 350 Ksi to about 750 Ksi, but most preferably, within the rangebetween 710 Ksi to 750 Ksi. Also as an example, glass fibers can beselected having a tensile strength above 180 Ksi, and more preferablywithin the range of about 180 Ksi to about 220 Ksi. The tensile strengthof the composite core can be adjusted by combining glass fibers having alower tensile strength with carbon fibers having a higher tensilestrength. The properties of both types of fibers may be combined to forma new cable having a more desirable set of physical characteristics.

[0055] Composite cores of the present invention can have various fiberto resin volume fractions. The volume fraction is the area of fiberdivided by the total area of the cross section. A composite core of thepresent invention may comprise fibers embedded in a resin having atleast a 50% volume fraction. The fiber to resin ratio affects thephysical properties of the composite core member. In particular, thestrength, electrical conductivity, and coefficient of thermal expansionare functions of the fiber to resin volume. Generally, a higher volumefraction of fibers in the composite results in a higher tensile strengthfor the resulting composite. The weight of the fiber will determine theratio of fiber to resin by weight. In accordance with the invention, themore preferred volume fraction of fiber to resin composite is 60% orlower or most preferably from about 50% to about 60%. The volumefraction can be adjusted to yield a fiber to resin ratio of 72% or lowerby weight, or more preferably from 65% to 72%, and most preferably 65%by weight.

[0056] Any layer or section of the composite core may have a differentfiber to resin ratio by weight relative to the other layers or sections.These differences may be accomplished by selecting the choosing anappropriate number of fibers for the appropriate resin type to achievethe desired fiber to resin ratio. For example, a composite core memberhaving a carbon fiber and epoxy layer surrounded by an outer glass andepoxy layer may comprise 126 spools of glass fiber and an epoxy resinhaving a viscosity of about 2000 cPs to about 6000 cPs at 50° C. Thisfiber to resin selection can yield a fiber to resin ratio of about 75/25by weight. Preferably, the resin may be modified to achieve the desiredviscosity for the forming process. The exemplary composite may also have16 spools of carbon fiber and an epoxy resin having a viscosity of about2000 cPs to about 6000 cPs at 50° C. This selection can yield a fiber toresin ratio of about 70/30 by weight. Changing the number of spools offiber changes the fiber to resin by weight ratio, and thereby can changethe physical characteristics of the composite core. Alternatively, theresin may be adjusted to increase or decrease the resin viscosity toimprove wetting.

[0057] Composite cores may have various geometries. Some of thedifferent embodiments of the various geometries will be explained below.However, the invention is not limited to these embodiments of thegeometries. First, fibers may have various alignments or orientations.Continuous towing can longitudinally orient the fibers along the cable.The core may have a longitudinal axis running along the length of thecable. In the art, this longitudinal axis is referred to as the 0°orientation. In most cores, the longitudinal axis runs along the centerof the core. Fibers can be arranged to parallel this longitudinal axis;this orientation is often referred to as a 0° orientation orunidirectional orientation. However, other orientations may be possible.

[0058] The fibers in the composite core may be arranged in various wayswithin the core. Besides the 0° orientation, the fibers may have otherarrangements. Some of the embodiments may include off-axis geometries.One embodiment of the composite core may have the fibers helically woundabout the longitudinal axis of the composite core. The winding of thefibers may be at any angle from near 0° to near 90° from the 0°orientation. The winding may be in the + and − direction or in the + or− direction. In other words, the fibers may be wound in a clockwise orcounterclockwise direction. In an exemplary embodiment, the fibers wouldbe helically wound around the longitudinal axis at an angle to thelongitudinal axis. In some embodiments, the core may not be formed inradial layers. Rather, the core may have two or more flat layers thatare compacted together into a core. In this configuration, the fibersmay have other fiber orientation besides 0° orientation. The fibers maybe laid at an angle to the 0° orientation in any layer. Again, the anglemay be any angle + or − from near 0° to near 90°. In some embodiments,one fiber or group of fibers may have one direction while another fiberor group of fibers may have a second direction. Thus, the presentinvention includes all multidirectional geometries. One skilled in theart will recognize other possible angular orientations.

[0059] In some other embodiments, the fibers may be interlaced orbraided. In this embodiment, one set of fibers may be helically wound inone direction while a second set of fibers is wound in the oppositedirection. As the fibers are wound, one set of fibers may changeposition with the other set of fibers. In other words, the fibers wouldbe woven or crisscrossed. These sets of helically wound fibers also maynot be braided or interlaced but may form concentric layers in the core.In another embodiment, a braided sleeve may be placed over the core andembedded in the final core configuration. Also, the fibers may betwisted upon themselves or in groups of fibers. One skilled in the artwill recognize other embodiments where the fiber orientation isdifferent. Those different embodiments are included within the scope ofthe invention.

[0060] Other geometries are possible beyond the orientation of thefibers. The composite core may be formed in different layers andsections. A two layered composite core is provided as an example in FIG.11. Several other core arrangements are possible. First, a compositecore formed from more than two layers is possible. A first layer mayhave a first fiber type and a first type of matrix. Other layers mayhave different fiber types and different matrices from the first layer.The different layers may be bundled and compacted into a final compositecore. As an example, the composite core may consist of a layer made fromcarbon and epoxy, a glass fiber and epoxy layer, and then a basalt fiberand epoxy layer. In another example, the inner lay may be basalt,followed by a carbon layer, followed by a glass layer, and finally beanother basalt layer. All of these different arrangements can producedifferent physical properties for the composite core. One skilled in theart will recognized the numerous other layer configurations that arepossible.

[0061] Still another core arrangement may include different sections inthe core instead of layers. FIG. 5 shows numerous possible crosssectional views of these types of composite cores. These cross sectionsdemonstrate that the composite core may be arranged in two or moresections without those sections being layered. Thus, depending on thephysical characteristics desired, the composite core can have a firstsection of core with a certain composite and one or more other sectionswith a different composite. These sections can each be made from aplurality of fibers from one or more fiber types embedded in one or moretypes of matrices. The different sections may be bundled and compactedinto a final core configuration.

[0062] In any of these different arrangements, the layers or sectionsmay have different fibers or different matrices. For example, onesection of the core may be a carbon fiber embedded in a thermosettingresin. Another section may be a glass fiber embedded in a thermoplasticsection. Each of the sections may be uniform in matrix and fiber type.However, the sections and layers may also be hybridized. In other words,any section or layer may be formed from two or more fiber types. Thus,the section or layer may be, as an example, a composite made from glassfiber and carbon fiber embedded in a resin. Thus, the composite cores ofthe present invention can form a composite core with only one fiber typeand one matrix, a composite core with only one layer or section with twoor more fiber types and one or more matrices, or a composite core formedfrom two or more layers or sections each with one or more fiber typesand one or more matrix types. One skilled in the art will recognize theother possibilities for the geometry of the composite core.

[0063] As explained above, some embodiments of the composite core maycombine two or more types of fibers to take advantage of the inherentphysical properties of each fiber type to create different compositecores. For example, two or more fiber type reinforcements may becombined to form a high strength and high stiffness composite core butwith added flexibility. Also, the physical characteristics of thecomposite core may be adjusted by changing the fiber to resin ratio ofeach component. In one example, the composite core may be 0.1104 sq. in.in cross sectional area for a core of 0.375 inches in diameter andcomprise a layer of carbon fiber and a layer of glass fiber. The carbonfiber and matrix section or inner layer may be 0.0634 sq. in. in crosssectional area. The glass fiber and matrix section or layer may be0.0469 sq. in. in cross sectional area. This composite core may comprisean inner core with a fiber to resin ratio of about 70/30 by weight andan outer layer having a fiber to resin ratio of about 75/25 by weight.This fiber and core arrangement produces a high strength core, which isalso flexible. Other fibers and other geometries may produce compositecores with different physical properties.

[0064] The physical characteristics of the composite core may also beadjusted by adjusting the area percentage of each component within thecomposite core member. For example, by reducing the total area of carbonin the composite core mentioned earlier from 0.0634 sq. in. andincreasing the area of the glass layer from 0.0469 sq. in., thecomposite core member product can have reduced stiffness and increasedflexibility. Alternatively, a third fiber, for example basalt, may beintroduced into the composite core. The additional fiber changes thephysical characteristics of the end product. For example, bysubstituting basalt for some carbon fibers, the core may have increaseddielectric properties and a relatively small decrease in core stiffness.

[0065] In accordance with the present invention, the composite core isdesigned based on the desired physical characteristics of an ACCCreinforced cable. An exemplary embodiment is provided below. Thecomposite core can be designed having an inner strengthening core membercomprising a high-strength composite surrounded by an outerlow-stiffness layer. The high-strength composite can have a greater than50% volume fraction and mechanical properties exceeding the mechanicalproperties of glass fibers. The outer layer of low-stiffness compositecan have mechanical properties in the range of glass fiber. Themechanical properties of fibers similar to glass fibers can addflexibility to the composite core.

[0066] Fibers forming the first layer of a high-strength composite canbe selected with a tensile strength within the range of about 350 Ksi toabout 750 Ksi; a modulus of elasticity within the range of about 22 Msito about 37 Msi; a coefficient of thermal expansion within the range ofabout −0.7×110 m/m/° C. to about 0 m/m/° C.; a yield elongation percentwithin the range of about 1.5% to 3%; a dielectric within the range ofabout 0.31 W/m·K to about 0.04 W/m·K; and a density within the range ofabout 0.065 lb/in³ to about 0.13 lb/in³.

[0067] Fibers forming the outer layer of a low-stiffness layer can havea tensile strength within the range about 180 Ksi to 220 Ksi; a modulusof elasticity within the range of about 6 Msi to 7 Msi; a coefficient ofthermal expansion within the range of about 5×10⁻⁶ m/m/° C. to about10×10⁻⁶ m/m/° C.; a yield elongation percent within the range of about3% to about 6%; a dielectric within the range of about 0.034 W/m·K toabout 0.04 W/m·K; and a density from 0.060 lbs/in³ and up, but morepreferably from about 0.065 lbs/in³ to about 0.13 lbs/in.

[0068] The layers may be bundled in a single core. These layers ofdiffering composites form a hybridized composite core. Although otherarrangements of the layers are possible, preferably, the layers would beconcentric. Thus, the layers form a hybridized, concentric core with twouniform layers each created from one fiber type and one matrix material.

[0069] In the exemplary embodiment, the composite core can have thefollowing physical characteristics. The core can have a tensile strengthin the range within the range of about 160 Ksi to about 380 Ksi. Morepreferably, the core has a tensile strength of about 300 Ksi and above.The core can have a modulus of elasticity within the range of about 7Msi to about 37 Msi, more preferably, about 16 Msi. The core canwithstand operating temperature in the range of about 45° C. andpossibly up to about 230° C. More preferably, the composite core is ableto withstand an operating temperature around 180° C. and above. Thecomposite core can have a coefficient of thermal expansion of about 0m/m/° C. to about 6×10⁻⁶ m/m/° C., more preferably, about 2.5×10⁻⁶ m/m/°C. A composite core member having an inner layer and an outer layer inaccordance with the ranges set forth above can have increased ampacityover other prior art conductor cables of similar diameter by about 1% toabout 200%. This ampacity gain may also be achieved even if the priorart cable has a similar conductor configuration.

[0070] Sag versus temperature is determined by considering the modulusof elasticity, the coefficient of thermal expansion, the weight of thecomposite strength member, and the conductor weight. An ACCC cable canachieve ampacity gains and operating temperatures between 45° C. and230° C. because the higher modulus of elasticity and lower coefficientof thermal expansion in the composite cores. To design an ACCC cablewith increased ampacity ability, the composite core should prevent sagat the higher operating temperatures that may accompany ampacity gains.Sag versus temperature calculations require input of the modulus ofelasticity, coefficient of thermal expansion, the weight of thecomposite strength member, and the conductor weight. Accordingly, thesephysical characteristics are taken into account in designing thecomposite core. The composite core of the present invention can haveboth a high modulus of elasticity and a low coefficient of thermalexpansion. Also, the fibers can have high dielectric properties. Thus,an ACCC cable of the present invention can operate at higher operatingtemperatures without a corresponding increase in sag.

[0071] As another example of the composite core, it may be feasible tomake a composite core comprising interspersed high modulus of elasticityfibers and low modulus of elasticity fibers. Depending on the strain tofailure ratio, this type of core may be a single section or layer ofhybridized composite or it may be formed in several sections of singlefiber composite. Carbon fibers can be selected for their high modulus ofelasticity within the range of about 22 Msi to about 37 Msi, a lowcoefficient of thermal expansion within the range of about −0.7×10⁻⁴m/m/° C. to about 0 m/m/° C., and an elongation percent within the rangeof about 1.5% to about 3%. Glass fibers are selected for a low modulusof elasticity within the range of about 6 Msi to about 7 Msi, a lowcoefficient of thermal expansion within the range of about 5×10⁻⁴ m/m/°C. to about 10×10⁻⁴ m/m/° C., and an elongation percent within the rangeof about 3% to about 6%. The strain capability of this exemplarycomposite is a function of the inherent physical properties of thecomponents and the volume fraction of components. In accordance with thepresent invention, the resins can be customized to achieve certainproperties for processing and to achieve desired physical properties inthe end product. As such, the fiber and customized resin strain tofailure ratio can be determined. For example, carbon fiber and epoxy hasa strain to failure ratio of 2.1% and glass fiber and epoxy has a strainto failure ratio of 1.7%. Accordingly, the composite core can bedesigned to have the stiffness of the carbon fiber and epoxy and theflexibility of the glass fiber and epoxy. This combination of fibers andresin can create a composite core that is flexible and has a lowcoefficient of thermal expansion.

[0072] Alternatively, another high-strength composite having mechanicalproperties in excess of glass fiber could be substituted for at least aportion of the carbon fibers and another fiber having the mechanicalproperty range of glass fiber could be substituted for glass fiber. Forexample, basalt has the following properties: a high tensile strength inthe range of about 701.98 Ksi (compared to the range of about 180 toabout 500 Ksi for glass fibers), a high modulus of elasticity in therange of about 12.95 Msi, a low coefficient of thermal expansion in therange of about 8.0 ppm/C (compared to about 5.4 ppm/C for glass fibers),and an elongation percent in the range of about 3.15% (compared therange of about 3% to about 6% for glass fibers). The basalt fibers canprovide increased tensile strength, a modulus of elasticity betweencarbon and glass fiber, and an elongation percent close to that ofcarbon fibers. A further advantage is that basalt has superiordielectric properties to carbon. The composite core can comprise aninner strength member that is non-conductive. By designing ahigh-strength composite core having fibers of inherent physicalcharacteristics surrounded by low modulus fiber outer core, a newproperty set for the composite core is obtained.

[0073] The composite core may also include other surface applications orsurface treatments to the composite core. For instance, the compositecore may include any chemical or material application to the core thatprotects the core from environmental factors, protects the core fromwear, or prepares the core for further processing. Some of these typesof treatments may include, but are not limited to, gel coats, protectivepaintings, finishes, abrasive coatings, or the like. Some of thematerial applications may include, but are not limited to, surface veilsapplied to the core, mats applied to the core, or protective orconductive tapes wrapped around the core. The tape may include dry orwet tapes. The tapes may include, but are not limited to, paper orpaper-product tapes, metallic tape (like aluminum tape), polymerictapes, rubber tapes, or the like. Any of these products may protect thecore from environmental forces like moisture, heat, cold, UV radiation,or corrosive elements. Other applications and treatments to the corewill be recognized by one skilled in the art and are included in thepresent invention.

[0074] The final ACCC reinforced cable is created by surrounding thecomposite core with an electrical conductor. Putting the conductoraround the core is explained in more detail below.

[0075] The composite cables made in accordance with the presentinvention exhibit physical properties wherein these certain physicalproperties may be controlled by changing parameters during the compositecore forming process. More specifically, the composite core formingprocess is adjustable to achieve desired physical characteristics in afinal ACCC cable.

[0076] A Method of Manufacture of a Composite Core for an ACCCreinforced Cable

[0077] Several forming processes to create the composite core may exist,but an exemplary process is described hereinafter. This exemplaryprocess is a high-speed manufacturing process for composite cores. Manyof the processes, including the exemplary process, can be used to formthe several different composite cores with the several different corestructures mentioned or described earlier. However, the description thatfollows chooses to describe the high-speed processing in terms ofcreating a carbon fiber core with a glass fiber outer layer, havingunidirectional fibers, and a uniformly layered, concentric compositecore. The invention is not meant to be limited to that one embodiment,but encompasses all the modifications needed to use the high-speedprocess to form the composite cores mentioned earlier. Thesemodifications will be recognized by one skilled in the art.

[0078] In accordance with the invention, a multi-phase B-stage formingprocess produces a composite core member from substantially continuouslengths of suitable fiber tows and heat processible resins. Afterproducing an appropriate core, the composite core member can be wrappedwith high conductivity material.

[0079] A process for making composite cores for ACCC cables according tothe invention is described as follows. Referring to FIG. 1, theconductor core B-stage forming process of the present invention is shownand designated generally by reference number 10. The B-stage formingprocess 10 is employed to make continuous lengths of composite coremembers from suitable fiber tows or rovings and resins. The resultingcomposite core member comprises a hybridized concentric core having aninner and outer layer of uniformly distributed substantially parallelfibers.

[0080] In starting the operation, the pulling and winding spoolmechanism is activated to commence pulling. The unimpregnated initialfiber tows, comprising a plurality of fibers extending from the exit endof the cooling portion in zone 9, serve as leaders at the beginning ofthe operation to pull fiber tows 12 from spools 11 through fiber towguide 18 and the composite core processing system.

[0081] In FIG. 1, multiple spools of fiber tows 12 are contained withina rack system 14 and are provided with the ends of the individual fibertows 12, leading from spools 11, being threaded through a fiber towguide 18. The fibers can be unwound, either using tangent pulling orcenter pulling, but preferably using tangent pulling to prevent twistedfibers. Preferably, a puller 16 at the end of the apparatus pulls thefibers through the apparatus. Each dispensing rack 14 can comprise adevice allowing for the adjustment of tension for each spool 11. Forexample, each rack 14 may have a small brake at the dispensing rack toindividually adjust the tension for each spool. Tension adjustmentminimizes caternary and cross-over of the fiber when it travels and aidsin the wetting process. The tows 12 are pulled through the guide 18 andinto a preheating oven 20 that evacuates moisture. The preheating oven20 uses continuous circular air flow and a heating element to keep thetemperature constant. The preheating oven is preferably above 100° C.

[0082] The tows 12 are pulled into a wet out system 22. The wet outsystem may be any process or device that can wet the fibers orimpregnate the fibers with resin. Wet out systems may includeincorporating the resin in a solid form that will be liquefied duringlater heating. For instance, a thermoplastic resin may be formed asseveral fibers. These fibers may be interspersed with the carbon andglass fibers of the exemplary embodiment. When heat is applied to thebundle of fibers, the thermoplastic fibers liquefy or melt andimpregnate or wet the carbon and glass fibers. In another embodiment,the carbon and glass fibers may have a bark or skin surrounding thefiber; the bark holds or contains a thermoplastic or other type resin ina powder form. When heat is applied to the fibers, the bark melts orevaporates, the powdered resin melts, and the melted resin wets thefibers. In another embodiment, the resin is a film applied to the fibersand then melted to wet the fibers. In still another embodiment, thefibers are already impregnated with a resin—these fibers are known inthe art as pre-preg tows. If the pre-preg tows are used, no wet out tankor device is used. An embodiment of the wet out system is a wet outtank. Hereinafter, a wet out tank will be used in the description, butthe present invention is not meant to be limited to that embodiment.Rather, the wet out system may be any device to wet the fibers. The wetout tank 22 is filled with resin to impregnate the fiber tows 12. Excessresin is removed from the fiber tows 12 during wet out tank 22 exit. Thefiber tows 12 are pulled from the wet out tank 22 to a secondary system,a B-stage oven 24. The B-stage oven heats the resin to a temperaturechanging the liquid stage of resin to a semi-cure stage. B-stage cureresin is in a tacky stage which permits the fiber tows 12 to be bent,compacted, bundled, and configured. The tackiness of the resin iscontrolled mainly by the resin heating temperature, which may come fromeither the tooling, the fiber, or the oven. Fiber tows 12 separated bythe guide 18 are pulled into a second B-stage oven 26 comprising aplurality of consecutive dies to compact and configure the tows 12. Twoor more dies may be an implement to compact, to drive air out of thecomposite, and to shape the fibers into a composite core. An embodimentof the set of dies is a set of bushings. A bushing may be a rigid platewith a plurality of passageways that accept the impregnated fibers.Hereinafter, bushing will be used interchangeably with dies, but theinvention is not limited to that one embodiment. In the second B-stageoven 26, the fiber tows 12 are directed through a plurality ofpassageways provided by the bushings. In an exemplary embodiment, thecomposite core is made from two sets of fiber tows—inner segments areformed from carbon while the outer segments are formed from glass. Theconsecutive passageways continually compact and configure the innerfiber tows 12 into the inner composite segments. These inner segmentsare compacted together to form the inner carbon core. The outer fibertows are also continually compacted and configured into the outer layer,glass segments. After the inner core is formed, the outer segments maybe deposited onto and compacted with the inner core. The compaction ofall the segments creates a uniformly distributed, layered, andconcentric final composite core with the requisite outside diameter.

[0083] Preferably, the composite core member is pulled from the secondB-stage oven 26 to a next oven processing system 28 wherein thecomposite core member is cured and pulled to a next cooling system 30for cooling. After cooling, the composite core may be pulled to a nextoven processing system 32 for post curing at elevated temperature. Thepost-curing process promotes increased cross-linking within the resinresulting in improved physical characteristics of the composite member.The process generally can allow an interval between the heating andcooling process and the pulling apparatus 36 to cool the productnaturally or by convection such that the pulling device 34 used to gripand pull the product will not damage the product. The pulling mechanismpulls the product through the process with precision controlled speed.

[0084] Referring now more particularly to FIG. 1, in an exemplaryembodiment, the process continuously pulls fiber from left to right ofthe system through a series of phases referred to herein as zones. Eachzone performs a different processing function. In this particularembodiment, the process comprises 9 temperature and compacting zones.The process originates at a series of fiber dispensing racks 14 wherebya caterpuller 34 can continuously pull the fibers 12 through each zone.One advantage to the caterpuller system is that it functions as acontinuous pulling system driven by an electrical motor as opposed tothe traditional reciprocation system. The caterpuller system uses asystem of two belts traveling on the upper and lower portions of theproduct squeezing the product there between. Accordingly, thecaterpuller system embodies a simplified uniform pulling systemfunctioning at precision controlled speed using only one device insteadof a multiplicity of interacting parts functioning to propel the productthrough the process. Alternatively, a reciprocation system may be usedto pull the fibers through the process.

[0085] The process starts with zone 1. Zone 1 may comprise a type offiber dispensing system. In one embodiment, the fiber dispensing systemcomprises two racks 13 each rack containing a plurality of spools 11containing fiber tows 12. Further, the spools 11 are interchangeable toaccommodate varying types of fiber tows 12 depending on the desiredproperties of the composite core member.

[0086] For example, an exemplary composite core member formed by theB-stage forming process comprises a carbon and resin inner coresurrounded by a glass and resin outer core layer. Preferably, highstrength and high quality carbon is used. The resin also protects thefibers from surface damage, and prevents cracking through a mass offibers improving fracture resistance. The conductor core B-stage formingprocess 10 creates a system for pulling the fibers to achieve theoptimum degree of bonding between fibers in order to create a compositemember with optimal composite properties.

[0087] As previously mentioned, the components of the composite core areselected based on desired composite core characteristics. One advantageof the present process is the ability to adjust composite components inorder for a composite core to achieve the desired goals of a final ACCCcable. It is preferable to combine types of fibers to combine thephysical characteristics of each. Performance can be improved by forminga core with increased strength and stiffness, coupled with a moreflexible outer layer. The process can increase the optimalcharacteristics of the composite by preventing twisting of rovingsleading to more uniform wetting and strength characteristics.

[0088] For example, in an exemplary embodiment of the composite coremember, the composite core comprises glass and carbon. Using the B-stageforming process, the racks 13 may hold 126 spools 11 of glass and 16spools 11 of carbon. The fiber tows 12 leading from spools 11 arethreaded through a fiber tow guide 18 wherein fiber tow passageways arearranged to provide a configuration for formation of a core compositesections having an inner carbon core and outer glass layer. The carbonlayer is characterized by high strength and stiffness and is a weakelectrical conductor whereas the outer low modulus glass layer is moreflexible and non-conductive. Having an outer glass layer provides anouter insulating layer between the carbon and the high conductivityaluminum wrapping in the final composite conductor product.

[0089] The fiber dispensing system dispenses fibers from the fiberpackage pull. Preferably, a tangent pull method may be used because itdoes not twist the fiber. The center pull method can twist fibersdispensed from the spool. As such, the center pull method can result inan increased number of twisted fibers. Twisted fiber can occasionallylay on top of other twisted fiber and create a composite with spots ofdry fiber. It is preferable to use tangent pull method to avoid dryspots and optimize wet out ability of the fibers.

[0090] The fiber tows 12 are threaded through a guidance system 18. Theguide 18 can comprise polyethylene and steel dies or bushings containinga plurality of passageways in a predetermined pattern guiding the fibersto prevent the fibers from crossing. Referring to FIG. 2, the guide maycomprise a bushing with sufficiently spaced passageways for insertion ofthe fibers in a predetermined pattern. The passageways can be containedwithin an inner square portion 40. The passageways may be arranged inrows of varying number. The larger diameter carbon fibers can passthrough the center two rows of passageways 42 and the smaller diameterglass fibers pass through the outer two rows 44 on either side of thecarbon passageways 42. A tensioning device, preferably on each spool,can adjust the tension of the pulled fibers and may assure the fibersare pulled straight through the guide 18.

[0091] At least two fibers are pulled through each passageway in theguide 18. For example, a guide 18 comprising 26 passageways pulls 52fibers through. If a fiber of a pair breaks, a sensing system can alertthe composite core B-stage forming process 10 that there is a brokenfiber and may stop the puller 34. Alternatively, in one embodiment, abroken fiber can alert the process and the repair can be made withoutstopping the process. To repair, a new fiber can be pulled from the rack13 and glued or mechanically coupled or connected to the broken end ofthe new fiber. After the fiber is repaired, the conductor core B-stageforming machine 10 may be started again.

[0092] In an exemplary example, the fibers are grouped in a parallelarrangement for a plurality of rows. For example, in FIG. 2, there aresix parallel rows of passageways. The outer two rows comprise 32passageways, the two inner rows comprise 31 passageways, and the twocenter rows comprise 4 passageways each. Fibers are pulled at least twoat a time into each passageway and pulled into zone 2.

[0093] Zone 2 comprises an oven processing system that preheats the dryfibers to evacuate any moisture. The fibers of the present invention maybe heated within the range of about 150° F. to 300° F. to evaporatemoisture.

[0094] The oven processing system comprises an oven portion wherein theoven portion is designed to promote cross-circular air flow against theflow of material. FIG. 9 illustrates a typical embodiment of the ovensystem. An oven is generally designated 60. The fibers pass through theoven from upstream to downstream direction, the air passes in thereverse direction. The oven processing system comprises an air-heatingdrive system housing 64 that houses a blower 68, powered by electricmotor 70, located upstream from a heater assembly 66 to circulate air ina downstream direction through an air flow duct 62. The heat drivesystem housing houses a blower 68 upstream of the heater assembly 66.The blower 68 propels air across the heater assembly 66 and through theoven system. The air flows downstream to a curved elbow duct 72. Thecurved elbow duct 72 shifts the air flow 90 degrees up into an inletduct 78 and through the oven inlet 76. Through the inlet, the air flowshifts 90 degrees to flow upstream through the oven 60 against the pulldirection of the fibers. At the end of the oven 60, the air flow shifts90 degrees down through the oven outlet 80 then through the outlet duct74 then through the blower 68 and back into the heat drive systemhousing 64. In one embodiment, a valve is placed between the outlet duct74 and the blower 68. This valve may function to fully or partiallyrestrict the air flow in either direction. In a further embodiment, alouver or vent to the outside air is set between the valve and theblower. The louver can open to let in cooler air from the environment tohelp cool the over temperature quickly. The motor 70 comprises anelectrical motor outside of the heat drive system to preventoverheating. The motor 70 comprises a pulley with a timing belt thatmoves the bladed blower 68. Preferably, the system is computercontrolled allowing continuous air circulation at a desired temperature.More preferably, the process allows for the temperature to change at anytime according to the needs of the process.

[0095] For example, the computer may sense the temperature is not at therequired temperature and can activate or deactivate the heater 66. Theblower 68 blows air across the heating element 66 downstream. The systemforces the air to travel in a closed loop circle continuouslycirculating through the oven 60 keeping the temperature constant.

[0096]FIG. 10 is a more detailed view of an exemplary embodiment of theheating element 66. In one embodiment, the heater assembly 66 comprisesnine horizontal steel electrical heaters 82. Each heater unit isseparate and distinct from the other heater. Each heater unit isseparated by a gap. Preferably, after sensing a temperaturedifferential, the computer activates the number of heaters to providesufficient heat. If the system requires the computer activates one ofnine heaters. Alternatively, depending on the needs of the process, thecomputer activates every other heater in the heater assembly. In anotherembodiment the computer activates all heaters in the heater assembly. Ina further alternative, the computer activates a portion of the heatersin the heater assembly or turns all the heaters off.

[0097] In an alternate embodiment, electromagnetic fields penetratethrough the process material to heat the fibers and drive off anymoisture. In another embodiment pulsed microwaves heat the fibers anddrive off any moisture. In another embodiment, an electron beam useselectrons as ionizing radiation to drive off any excess moisture.

[0098] In another embodiment, the caterpuller can pull the fibersthrough zone 3, the fiber impregnation system. Zone 3 comprises a wetout system 22. There are several embodiments of a wet out system. Someof these embodiments will be explained below. However, the presentinvention is not limited to those described embodiments. In an exemplaryembodiment, a pass-through tank is used. The pass-through tank has anenclosed tank where the fiber rovings enter through a bushing at one endof the tank and pass through the resin until exiting another bushing atthe other end of the tank. A pass-through tank 22 can contain a devicethat allows the redirection of fibers during wet out. Preferably, a setof redirection bars may be located in the center of the tank and movethe fibers vertically up or down compared to the direction of the pull,whereby the deflection causes the fibers to reconfigure from a roundconfiguration to a flat configuration. The flat configuration allows thefibers to lie side by side and allows for the fibers to be morethoroughly wetted by the resin.

[0099] Various alternative techniques well known in the art can beemployed to apply or impregnate the fibers with resin. Such techniquesinclude for example, spraying, dipping, reverse coating, brushing, andresin injection. In an alternate embodiment, ultrasonic activation usesvibrations to improve the wetting ability of the fibers. In anotherembodiment, a dip tank may be used to wet out the fibers. A dip tank hasthe fibers drop into a tank filled with resin. When the fibers emergefrom the tank filled with resin, the fibers are wetted. Still anotherembodiment may include an injection die assembly. In this embodiment,the fibers enter a pressurized tank filled with resin. The pressurewithin the tank helps wet the fibers. The fibers can enter the die forforming the composite while still within the pressurized tank. Oneskilled in the art will recognize other types of tanks and wet outsystems that may be used.

[0100] Generally, any of the various known resin compositions can beused with the invention. In an exemplary embodiment, a heat curablethermosetting polymeric may be used. The resin may be for example, PEAR(PolyEther Amide Resin), Bismaleimide, Polyimide, liquid-crystal polymer(LCP), vinyl ester, high temperature epoxy based on liquid crystaltechnology, or similar resin materials. One skilled in the art willrecognize other resins that may be used in the present invention. Resinsare selected based on the process and the physical characteristicsdesired in the composite core.

[0101] Further, the viscosity of the resin affects the rate offormation. To achieve the desired proportion of fiber to resin forformation of the composite core member, preferably, the viscosity rangeof the resin is within the range of about 50 Centipoise to about 3000Centipoise at 20° C. More preferably, the viscosity falls in the rangeof about 50 Centipoise to about 600 Centipoise at 20° C. The resin isselected to have good mechanical properties and excellent chemicalresistance to prolonged environmental exposure of at least 60 years andmore preferably, at least 70 years at operation up to about 230° C. Aparticular advantage of the present invention is the ability for theprocess to accommodate use of low viscosity resins. In accordance withthe present invention, it is preferable to achieve a fiber to resinratio within the range of 62-75% by weight. It is more preferable tohave a fiber to resin ratio within the range of 69-75% by weight. Lowviscosity resins will sufficiently wet the fibers for the composite coremember. A preferred polymer provides resistance to a broad spectrum ofaggressive chemicals and has very stable dielectric and insulatingproperties. It is further preferable that the polymer meets ASTME595outgassing requirements and UL94 flammability tests and is capable ofoperating intermittently at temperatures ranging between 220° C. and280° C. without thermally or mechanically damaging the strength of themember.

[0102] To achieve the desired fiber to resin wetting ratio, the upstreamside of the wet out tank can comprises a device to extract excess resinfrom the fibers. In one embodiment, a set of wipers may be placed afterthe end of the wet out system, preferably made from steel chrome platedwiping bars. The wipers can be Dr. Blades or other device for removingexcess resin.

[0103] Alternatively, the wet out tank uses a series of squeeze outbushings to remove excess resin. During the wet out process each bundleof fiber contains as much as three times the desired resin for the finalproduct. To achieve the right proportion of fiber and resin in the crosssection of the composite core members, the amount of pure fiber iscalculated. The squeeze out bushing or wipers is designed to removeexcess resin and control the fiber to resin ratio by volume. Forexample, where the bushing passageway is twice as big as the area of thecross section of the fiber, a resin to fiber ration by volume of 50%won't be pulled through the bushing, the excess resin will be removed.Alternatively, the bushing and wipers can be designed to allow passageof any ratio of fiber to resin by volume. In another embodiment, thedevice may be a set of bars that extract the resin. These resinextraction devices may also be used with other wet out systems. Inaddition, one skilled in the art will recognize other devices that maybe used to extract excess resin. Preferably, the excess resin iscollected and recycled into the wet out tank 22.

[0104] Preferably, a recycle tray extends lengthwise under the wet outtank 22 to catch overflow resin. More preferably, the wet out tank hasan auxiliary tank with overflow capability. Overflow resin is returnedto the auxiliary tank by gravity through the piping. Alternatively, tankoverflow can be captured by an overflow channel and returned to the tankby gravity. In a further alternate, the process can use a drain pumpsystem to recycle the resin back from the auxiliary tank and into thewet out tank. Preferably, a computer system controls the level of resinwithin the tank. Sensors detect low resin levels and activate a pump topump resin into the tank from the auxiliary mixing tank into theprocessing tank. More preferably, there is a mixing tank located withinthe area of the wet out tank. The resin is mixed in the mixing tank andpumped into the resin wet out tank.

[0105] The pullers pull the fibers from zone 3 to zone 4, the B-stagezone. Zone 4 comprises an oven processing system 24. Preferably, theoven processing system is an oven with a computer system that controlsthe temperature of the air and keeps the air flow constant wherein theoven is the same as the oven in zone 2.

[0106] The pullers pull the fibers from zone 3 to zone 4. The ovencirculates air in a circular direction downstream to upstream by apropeller heating system. The computer system controls the temperatureto heat the wet fiber to B-stage. Preferably, the process determines thetemperature. B-stage temperature of the present invention ranges fromwithin about 150° F. to about 300° F. This temperature is maintainedwithin the range in both the first B-stage oven and the second B-stageoven. One advantage of the B-stage semi-cure process in the presentinvention is the ability to heat the resin to a semi-cure state in ashort duration of time, approximately 1-1.5 minutes during thecontinuation of the process. The advantage is that the heating step doesnot affect the processing speed of the system. The B-stage processallows for the further tuning of the fiber to resin ratio by removingexcess resin from the wet-out stage. Further, B-stage allows the fiberto resin to be further compacted and configured during the process.Accordingly, the process differs from previous processes that usepre-preg semi-cure. Heating the core can semi-cure the resin and bringit to a tacky stage.

[0107] More specifically, in traditional composite processingapplications, the wetted fibers are heated gradually to a semi-curestage. However, the heating process generally takes periods of one houror longer to reach the semi-cure stage. Moreover, the composite must beimmediately wrapped and frozen to keep the composite at the semi-curestage and prevent curing to a final stage. Accordingly, the processingis fragmented because it is necessary to remove the product from theline to configure the product.

[0108] In accordance with the present invention, the B-stage heating isdedicated to a high efficiency commercial application wherein semi-cureis rapid, preferably 1-1.5 minutes during a continuous process.Preferably, the resins are designed to allow rapid B-stage semi-curingthat is held constant through the process allowing for shaping andconfiguring and further compaction of the product.

[0109] The pullers pull the fibers from B-stage zone 4 to zone 5 for theformation of the composite core member. Zone 5 comprises a next ovenprocessing system 26 having a plurality of dies. As stated above, thisB-stage oven is kept at a temperature from about 150° F. to about 300°F. The dies or bushings function to shape the cross section of the fibertows 12. Preferably, the bushings are configured in a series comprisinga parallel configuration with each other. In an exemplary embodiment,there is a set of seven bushings spaced laterally within the ovenprocessing system 26. Preferably, the spacing of the bushings isadjusted according to the process. The bushings can be spacedequidistance or variable distance from each other.

[0110] The series of bushings in zone 5 can minimize friction due to therelatively thin bushings ranging within about 3/8 to about {fraction(3/4)} inch thick. Minimizing friction aids in maximizing the processspeed.

[0111] Zones 4, 5 and 6 of the present invention extend within the rangeof about 30-45 feet. Most preferably, the zones 4, 5 and 6 extend atleast 30 feet. The pulling distance and the decreased friction due tothin bushing plates helps the process reach speeds in the range of about9 ft/min to about 60 ft/min. In an exemplary embodiment, the processingspeed is about 20 ft/min. Processing speed is further increased due tothe high fiber to resin ratio.

[0112] Referring to FIG. 3, for example, the bushings 90 comprise a flatsteel plate with a plurality of passageways through which the fiber tows12 are pulled. The flat plate steel bushing 90 preferably ranges from{fraction (3/8)} inch to ½ inch thick determined by the process. Thebushings 90 have relatively thin walls to reduce friction between thedie and the fast traveling fiber. The oven is long enough to allow thefiber to stay in the controllable B-stage temperature for a longerperiod of time. Thus, the length of the oven is related to the speed ofprocessing. The thickness of the bushing 90 is preferably the minimumneeded to compact the B-staged package into the final shape.

[0113] Preferably, the design and size of the bushings 90 are the same.More preferably, the passageways within each bushing 90 diminish in sizeand vary in location within each successive bushing 90 in the upstreamdirection. FIG. 3 illustrates an exemplary embodiment of a bushing 90.The bushing 90 comprises two hooked portions 94 and an inner preferablysquare portion 92. The inner square portion 92 houses the passagewaysthrough which the pulling mechanism pulls the fibers. The outer hookedportions 94 form a support system whereby the set of bushings 90 isplaced within the oven in zone 5. The outer hooked portion 94 connectswith interlocking long steel beams within the oven that function tosupport the bushings 90.

[0114] Zone 5 comprises a series of numerous consecutive bushings. Thebushings have two functions: (1) guide the fiber in the configurationfor the final product; and (2) shape and compact the B-staged fibers. Inone embodiment, the bushings 90 are placed apart within the ovensupported on the hooked structures. The bushings 90 function tocontinually compact the fibers and form a composite core comprising, inthis embodiment, carbon and glass while the process is under appropriatetension to achieve concentricity and uniform distribution of fiberwithout commingling of fibers. The bushings 90 may be designed to formbundles of a plurality of geometries. For example, FIG. 5 illustratesthe variations in cross sections that may be achieved in the compositemember. Each cross section results from different bushing 90 designs.

[0115] The passageways in each successive bushing 90 diminish in sizefurther compacting the fiber bundles. For example, FIG. 6 shows eachbushing 90 superimposed on top of one another. Several changes areapparent with each consecutive bushing 90. First, each overlaid bushing90 shows that the size of each passageway decreases. Second, thesuperimposed figure shows the appearance of the center hole forcompaction of the core element. Third, the figure shows the movement ofthe outer corner passageways towards the center position.

[0116] Referring to FIG. 4, there are two bushings illustrated. Thefirst bushing 100 illustrated, is in a similar configuration as theguide bushing 18. The second bushing 104 is the first in the series ofbushings that function to compact and configure the composite core. Thefirst bushing 100 comprises an inner square portion 92 with a pluralityof passageways 102 prearranged through which the fibers are pulled. Thepassageways 102 are designed to align the fibers into groups in bushingtwo 104 having four outer groups 106 of fibers and four inner groups 108of fibers. The inner square portion of the bushing 100 comprises sixrows of passageways 110. The arrangement of the passageways 110 may beconfigured into any plurality of configurations depending on the desiredcross section geometry of the composite core member. The top and bottomrow, 112 and 114 respectively, contain the same number of passageways.The next to top and next to bottom rows, 116 and 118 respectively,contain the same number of passageways and the two inner rows 120 and122 contain the same number of passageways.

[0117] In an exemplary embodiment, the top and bottom rows contain 32passageways each. The next level of rows contains 31 passageways each.The middle rows contain 4 passageways each. The pulling mechanism pullstwo fibers through each passageway. Referring to FIG. 4 for example, thepulling mechanism pulls 126 glass fibers through rows 112, 114, 116 and118. Further, the pulling mechanism pulls 16 carbon fibers through rows120 and 122.

[0118] Referring to FIG. 7, the next bushing, bushing three in theseries comprises an inner square portion 131 having four outer cornerpassageways 132 a, 132 b, 132 c and 132 d and four inner passageways 134a, 134 b, 134 c and 134 d. The fibers exit bushing two and are dividedinto equal parts and pulled through bushing three. Each passageway inbushing three comprises one quarter of the particular type of fiberpulled through bushing two. More specifically, the top two rows of thetop and the bottom of bushing two are divided in half whereby the righthalf of the top two rows of fibers are pulled through the right outercorner of bushing three. The left half of the top two rows of fibers arepulled through the upper left corner 132 a of bushing three 130. Theright half of the top two rows of fibers are pulled through the upperright corner 132 b of bushing three 130. The right half of the bottomtwo rows of fibers are pulled through the lower right corner 132 c ofbushing three. The left half of the bottom two rows of fibers are pulledthrough the lower left corner 132 d of bushing three 130. The inner tworows of bushing one are divided in half whereby the top right half ofthe top middle row of fibers is pulled through the inner upper rightcorner 134 b of bushing three 130. The left half of the top middle rowof fibers is pulled through the inner upper left corner 134 a of bushingthree 130. The right half of the lower middle row of fibers is pulledthrough the inner lower right corner 134 c of bushing three 130. Theleft half of the lower middle row of fibers is pulled through the innerlower left corner 134 d of bushing three 130. Accordingly, bushing three130 creates eight bundles of impregnated fibers that will be continuallycompacted through the succeeding bushings.

[0119] The puller pulls the fibers through bushing three 130 to bushingfour 140. Bushing four 140 comprises the same configuration as bushingthree 130. Bushing four 140 comprises a square inner portion 141 havingfour outer corner passageways 142 a, 142 b, 142 c and 142 d and fourinner passageways 144 a, 144 b, 144 c and 144 d. Preferably, the fourouter corner passageways 142 a-d and the four inner passageways 144 a-dare slightly smaller in size than the similarly configured passagewaysin bushing three 130. Bushing four 140 compacts the fibers pulledthrough bushing three.

[0120] The puller pulls the fibers from bushing four 140 to bushing five150. Preferably, the four outer corner passageways 152 a, 152 b, 152 cand 152 d and the four inner passageways 154 a, 154 b, 154 c and 154 dare slightly smaller in size than the similarly configured passagewaysin bushing four 140. Bushing five 150 compacts the fibers pulled throughbushing four 140.

[0121] For each of the successive bushings, each bushing creates abundle of fibers with an increasingly smaller diameter. Preferably, eachsmaller bushing wipes off excess resin to approach the optimal anddesired proportion of resin to fiber composition.

[0122] The puller pulls the fibers from bushing five 150 to bushing six160. Preferably, the four outer corner passageways 162 a, 162 b, 162 cand 162 d and the four inner passageways 164 a, 164 b, 164 c and 164 dare slightly smaller in size than the similarly configured passagewaysin bushing five 150. Bushing six 160 compacts the fibers pulled throughbushing five 150.

[0123] Bushing seven 170 comprises an inner square 171 having four outercorner passageways 172 a, 172 b, 172 c and 172 d and one innerpassageway 174. The puller pulls the fibers from the four innerpassageways 164 of bushing six 160 through the single inner passageway174 in bushing seven 170. The process compacts the product to a finaluniform concentric core. Preferably, fibers are pulled through the outerfour corners 172 a, 172 b, 172 c, 172 d of bushing seven 170simultaneous with compacting of the inner four passageways 164 frombushing six 160.

[0124] The puller pulls the fibers through bushing seven 170 to bushingeight 180. The puller pulls the inner compacted core 184 and the outerfour corners 182 a, 182 b, 182 c, 182 d migrate inwardly closer to thecore 184. Preferably, the outer fibers diminish the distance between theinner core and the outer corners by half the distance.

[0125] The puller pulls the fibers through bushing eight 180 to bushingnine 190. Bushing nine 190 is the final bushing for the formation of thecomposite core. The puller pulls the four outer fiber bundles and thecompacted core through a passageway 192 in the center of bushing nine190.

[0126] Preferably, bushing nine 190 compacts the outer portion and theinner portion creating an inner portion of carbon and an outer portionof glass fiber. FIG. 8 for example, illustrates a cross-section of acomposite cable. The example illustrates a composite core member 200having an inner reinforced carbon fiber composite portion 202 surroundedby an outer reinforced glass fiber composite portion 204.

[0127] Temperature is kept constant throughout zone 5. The temperatureis determined by the process and is high enough to keep the resin in asemi-cured state. At the end of zone 5, the product comprises the finallevel of compaction and the final diameter.

[0128] The puller pulls the fibers from zone 5 to zone 6 a curing stagepreferably comprising an oven with constant heat and airflow as in zone5, 4 and 2. The oven uses the same constant heating and cross circularair flow as in zone 5, zone 4 and zone 2. The process determines thecuring heat. The curing heat remains constant throughout the curingprocess. In the present invention, the preferred temperature for curingranges from about 300° F. to about 400° F. The curing process preferablyspans within the range of about 8 feet to about 15 feet. Morepreferably, the curing process spans about 10 feet in length. The hightemperature of zone 6 results in a final cure forming a hard resin. Zone6 may incorporate a bushing ten to assure that the final fiber compositecore member holds its shape. In addition, another bushing preventsblooming of the core during curing.

[0129] During the next stages the composite core member product ispulled through a series of heating and cooling phases. The post cureheating improves cross linking within the resin improving the physicalcharacteristics of the product. The pullers pull the fibers to zone 7, acooling device. Preferably, the mechanical configuration of the oven isthe same as in zones 2, 4, 5 and 6. More specifically, the devicecomprises a closed circular air system using a cooling device and ablower. Preferably, the cooling device comprises a plurality of coils.Alternatively, the coils may be horizontally structured consecutivecooling elements. In a further alternative, the cooling device comprisescooling spirals. The blower is placed upstream from the cooling deviceand continuously blows air in the cooling chamber in an upstreamdirection. The air circulates through the device in a closed circulardirection keeping the air throughout at a constant temperature.Preferably, the cooling temperature ranges from within about 30° F. toabout 180° F.

[0130] The pullers pull the composite member through zone 7 to zone 8,the post-curing phase. The composite core member is heated topost-curing temperature to improve the mechanical properties of thecomposite core member product. The temperature in this oven is kept inthe range from about 300° F. to about 400° F.

[0131] The pullers pull the composite core member through zone 8 to zone9, the post curing cooling phase. Once the composite core has beenreheated, the composite core is cooled before the puller grabs thecompacted composite core. Preferably, the composite core member coolsfor a distance ranging from about 8 feet to about 15 feet by airconvection before reaching the puller. Most preferably, the coolingdistance is about 10 feet.

[0132] The pullers pull the composite core member through the zone 9cooling phase into zone 10, a winding system whereby the fiber core iswrapped around a wheel for storage or transportation. It is critical tothe strength of the core member that the winding does not over stressthe core by bending. In one embodiment, the core does not have anytwist, but the fibers are unidirectional. A standard winding wheel has adiameter of 3.5 feet with the ability to store up to 40,000 feet of corematerial. The wheel is designed to accommodate the stiffness of thecomposite core member without forcing the core member into aconfiguration that is too tight. The winding wheel must also meet therequirements for transportation. Thus, the wheel must be sized to fitunder bridges and be carried on semi-trailer beds or train beds. In afurther embodiment, the winding system comprises a means for preventingthe wheel from reversing flow from winding to unwinding. The means canbe any device that prevents the wheel direction from reversing forexample, a clutch or a brake system.

[0133] In a further embodiment, the process includes a quality controlsystem comprising a line inspection system. The quality control processassures consistent product. The quality control system may includeultrasonic inspection of composite core members; record the number oftows in the end product; monitor the quality of the resin; monitor thetemperature of the ovens and of the product during various phases;measure formation; or measure speed of the pulling process. For example,each batch of composite core member has supporting data to keep theprocess performing optimally. Alternatively, the quality control systemmay also comprise a marking system. The marking system may include asystem to mark the composite core members with the product informationof the particular lot. Further, the composite core members may be placedin different classes in accordance with specific qualities, for example,Class A, Class B and Class C.

[0134] The fibers used to process the composite core members can beinterchanged to meet specifications required by the final composite coremember product. For example, the process allows replacement of fibers ina composite core member having a carbon core and a glass fiber outercore with high grade carbon and E-glass. The process allows the use ofmore expensive better performing fibers in place of less expensivefibers due to the combination of fibers and the small core sizerequired. In one embodiment, the combination of fibers creates a highstrength inner core with minimal conductivity surrounded by a lowmodulus nonconductive outer insulating layer. In another embodiment, theouter insulating layer contributes to the flexibility of the compositecore member and enables the core member to be wound, stored andtransported on a transportation wheel.

[0135] Changing the composite core design may affect the stiffness andstrength of the inner core. As an advantage, the core geometry may bedesigned to achieve optimal physical characteristics desired in a finalACCC cable. Another embodiment of the invention, allows for redesign ofthe composite core cross section to accommodate varying physicalproperties and increase the flexibility of the composite core member.Referring again to FIG. 5, the different composite shapes change theflexibility of the composite core member. The configuration of the fibertype and matrix material may also alter the flexibility. The presentinvention includes composite cores that can be wound on a winding wheel.The winding wheel or transportation wheel may be a commerciallyavailable winding wheel or winding drum. These wheels are typicallyformed of wood with an inside diameter of 3.5 feet or less. These wheelsare not made in larger diameters commercially. However, special wheelscan be made. However, these wheels with larger diameters still must beable to be transported. Thus, the wheel diameters and widths are limitedby transportation requirements. The wheel must be able to fit underbridges and be carried on a semi-trailer or a train bed. The compositecore of the present invention can be wound onto one of these windingwheels.

[0136] Stiffer cores may require a wheel diameter 7 feet or greaterdiameter, and these size winding wheels are not commercially viable. Inaddition, a winding wheel that size may not meet the transportationstandards to pass under bridges or fit on semi-trailers. Thus, stiffcores are not practical. To increase the flexibility of the compositecore, the core may be twisted or segmented to achieve a wrappingdiameter that is acceptable. In one embodiment, the core may include one360 degree twist of the fiber for every one revolution of core aroundthe wheel to prevent cracking. Twisted fiber is included within thescope of this invention and includes fibers that are twistedindividually or fibers that are twisted as a group. In other words, thefibers may be twisted as a roving, bundle, or some portion of thefibers. Alternatively, the core can be a combination of twisted andstraight fiber. The twist may be determined by the wheel diameter limit.The tension and compaction stresses on the fibers are balanced by thesingle twist per revolution.

[0137] Winding stress is reduced by producing a segmented core. FIG. 5illustrates some examples of possible cross section configurations ofsegmented cores. The segmented core under the process is formed bycuring the section as separate pieces wherein the separate pieces arethen grouped together. Segmenting the core enables a composite memberproduct having a core greater than 0.375 inches to achieve a desirablewinding diameter without additional stress on the member product.

[0138] Variable geometry of the cross sections in the composite coremembers may be possessed as a multiple stream. The processing system isdesigned to accommodate formation of each segment in parallel.Preferably, each segment is formed by exchanging the series ofconsecutive bushings for bushings having predetermined configurationsfor each of the passageways. In particular, the size of the passagewaysmay be varied to accommodate more or less fiber, the arrangement ofpassageways may be varied in order to allow combining of the fibers in adifferent configuration in the end product and further bushings may beadded within the plurality of consecutive bushings to facilitateformation of the varied geometric cross sections in the composite coremember. At the end of the processing system the five sections in fivestreams of processing are combined at the end of the process to form thecomposite cable core that form a unitary (one-piece) body.Alternatively, the segments may be twisted to increase flexibility andfacilitate winding.

[0139] The final composite core can be wrapped in lightweight highconductivity aluminum forming a composite cable. While aluminum is usedin the title of the invention and in this description, the conductor maybe formed from any highly conductive substance. In particular, theconductor may be any metal or metal alloy suitable for electricalcables. While aluminum is most prevalent, copper may also be used. Itmay also be conceivable to use a precious metal, such as silver, gold,or platinum, but these metals are very expensive for this type ofapplication. In an exemplary embodiment, the composite core cablecomprises an inner carbon core having an outer insulating glass fibercomposite layer and two layers of trapezoidal formed strands ofaluminum.

[0140] In one embodiment, the inner layer of aluminum comprises aplurality of trapezoidal shaped aluminum segments helically wound orwrapped in a counter-clockwise direction around the composite coremember. Each trapezoidal section is designed to optimize the amount ofaluminum and increase conductivity. The geometry of the trapezoidalsegments allows for each segment to fit tightly together around thecomposite core member.

[0141] In a further embodiment, the outer layer of aluminum comprises aplurality of trapezoidal shaped aluminum segments helically wound orwrapped in a clockwise direction around the composite core member. Anopposite direction of wrapping prevents twisting of the final cable.Each trapezoidal aluminum element fits tightly with the trapezoidalaluminum elements wrapped around the inner aluminum layer. The tight fitoptimizes the amount of aluminum and decreases the aluminum required forhigh conductivity.

EXAMPLE

[0142] A particular embodiment of the invention is now described whereinthe composite strength member comprises E-glass and carbon type 13sizing. E-glass combines the desirable properties of good chemical andheat stability, and good electrical resistance with high strength. Thecross-sectional shape or profile is illustrated in FIG. 8 wherein thecomposite strength member comprises a concentric carbon coreencapsulated by a uniform layer of glass fiber composite. In anexemplary embodiment the process produces a hybridized core membercomprising two different materials.

[0143] The fiber structures in this particular embodiment are 126 endsof E-glass product, yield 900, Veterotex Amer and 16 ends of carbonTorayca T7DOS yield 24K. The resin used is Aralite MY 721 from Vanticoor is JEFFCO 1401-16/4101-17 made by JEFFCO Products.

[0144] In operation, the ends of 126 fiber tows of E-glass and 16 fibertows of carbon are threaded through a fiber tow guide comprising tworows of 32 passageways, two rows inner of 31 passageways and twoinnermost rows of 4 passageways and into a preheating stage at 150° F.to evacuate any moisture. After passing through the preheating oven, thefiber tows are pulled through a wet out tank. In the wet out tank adevice effectually moves the fibers up and down in a vertical directionenabling thorough wetting of the fiber tows. On the upstream side of thewet out tank is located a wiper system that removes excess resin as thefiber tows are pulled from the tank. The excess resin is collected by aresin overflow tray and added back to the resin wet out tank.

[0145] The fiber tows are pulled from the wet out tank to a B-state oventhat semi-cures the resin impregnated fiber tows to a tack stage. Atthis stage the fiber tows can be further compacted and configured totheir final form in the next phase. The fiber tows are pulled to a nextoven at B-stage oven temperature to maintain the tack stage. Within theoven are eight consecutive bushings that function to compact andconfigure the fiber tows to the final composite core member form. Twofiber tow ends are threaded through each of the 134 passageways in thefirst bushing which are machined to pre-calculated dimensions to achievea fiber volume of 72 percent and a resin volume of 28 percent in thefinal composite core member. The ends of the fiber tows exiting frompassageways in the top right quarter comprising half of the two top rowsare threaded through passageways 132 of the next bushing; the ends ofthe fiber tows exiting from passageways in the top left quartercomprising half of the top two rows are threaded through passageway 136of the next bushing; the ends of the fiber tows exiting from passagewaysin the lower right quarter comprising half of the bottom two rows arethreaded through passageway 140 of the next bushing; the ends of thefiber tows exiting from passageways in the lower left quarter comprisinghalf of the bottom two rows are threaded through passageway 138 of thenext bushing; the right and left quarters of passageways in the middleupper row are threaded through passageways 142 and 144 of the nextbushing and the right and left quarters of passageways in the middlebottom row are threaded through passageways 134 and 146 respectively.

[0146] The fiber tows are pulled consecutively through the outer andinner passageways of each successive bushing further compacting andconfiguring the fiber bundles. At bushing seven, the fiber bundlespulled through the inner four passageways of bushing six are combined toform a composite core whereas the remaining outer passageways continueto keep the four bundles glass fibers separate. The four outerpassageways of bushing seven are moved inward in bushing eight, closerto the inner carbon core. The fiber tows are combined with the innercarbon core in bushing nine forming a hybridized composite core membercomprising an inner carbon core having an outer glass layer.

[0147] The composite core member is pulled from bushing nine to a finalcuring oven at an elevated temperature of 380° F. as required by thespecific resin. From the curing oven the composite core member is pulledthrough a cooling oven to be cooled to 150° F. to 180° F. After cooling,the composite core member is pulled through a post curing oven atelevated temperature, preferably to heat the member to at least B-stagetemperature. After post-curing, the member is cooled by air toapproximately 180° F. The member is cooled prior to grabbing by thecaterpuller. The core is finally fed onto a winding wheel having around6000 feet of storage.

EXAMPLE

[0148] An example of an ACCC reinforced cable in accordance with thepresent invention follows. An ACCC reinforced cable comprising fourlayers of components consisting of an inner carbon fiber and epoxylayer, a next glass fiber and epoxy layer and two layers of tetrahedralshaped aluminum strands. The strength member consists of a high-strengthcomposite T700S carbon fiber and epoxy having a diameter of about 0.2165inches, surrounded by an outer layer of R099-688 glass fiber and epoxyhaving a layer diameter of about 0.375 inches. The glass fiber and epoxylayer is surrounded by an inner layer of nine trapezoidal shapedaluminum strands having a diameter of about 0.7415 inches and an outerlayer of thirteen trapezoidal shaped aluminum strands having a diameterof about 1.1080 inches. In the cross section, the total area of carbonis about 0.037 in², of glass is about 0.074 in², of inner aluminum isabout 0.315 in² and outer aluminum is about 0.5226 in². The fiber toresin ratio in the inner carbon strength member is 70/30 by weight andthe outer glass layer fiber to resin ratio is 75/25 by weight.

[0149] The specifications are summarized in the following table: GlassVetrotex roving R099-686 (900 Yield) Tensile Strength, psi 298,103Elongation at Failure, % 3.0 Tensile Modulus, × 10⁶ psi 11.2 GlassContent, % 57.2

[0150] Carbon (graphite) Carbon: Torayca T700S (Yield 24 K) Tensilestrength, Ksi 711 Tensile Modulus, Msi 33.4 Strain 2.1% Density lbs/ft³0.065 Filament Diameter, in 2.8E−04

[0151] Epoxy Matrix System Araldite MY 721 Epoxy value, equ./kg 8.6-9.1Epoxy Equivalent, g/equ. 109-   Viscosity @ 50 C, cPs 3000-6000 Density@ 25 C lb/gal. 1.150-1.18  Hardener 99-023 Viscosity @ 25 C, cPs  75-300Density @ 25 C, lb/gal 1.19-1/22 Accelerator DY 070 Viscosity @ 25 C,cPs <50 Density @ 25 C, lb/gal 0.95-1.05

[0152] An ACCC reinforced cable having the above specifications ismanufactured according to the following. The process used to form thecomposite cable in the present example is illustrated in FIG. 1. First,126 spools of glass fiber tows 12 and 8 spools of carbon are set up inthe rack system 14 and the ends of the individual fiber tows 12, leadingfrom spools 11, are threaded through a fiber tow guide 18. The fibersundergo tangential pulling to prevent twisted fibers. A puller 16 at theend of the apparatus pulls the fibers through the apparatus. Eachdispensing rack 14 has a small brake to individually adjust the tensionfor each spool. The tows 12 are pulled through the guide 18 and into apreheating oven 20 at 150° F. to evacuate moisture.

[0153] The tows 12 are pulled into wet out tank 22. Wet out tank 22 isfilled with Araldite MY 721/Hardener 99-023/Accelerator DY070 toimpregnate the fiber tows 12. Excess resin is removed from the fibertows 12 during wet out tank 22 exit. The fiber tows 12 are pulled fromthe wet out tank 22 to a B-stage oven 24 and are heated to −200° F.Fiber tows 12 are kept separated by the guide 18 and are pulled into asecond B-stage oven 26 also at 200° F. comprising a plurality ofconsecutive bushings to compact and configure the tows 12. In the secondB-stage oven 26, the fiber tows 12 are directed through a plurality ofpassageways provided by the bushings. The consecutive passagewayscontinually compact and configure the fiber tows 12 into the finaluniform composite core member.

[0154] The first bushing has two rows of 32 passageways, two inner rowsof 31 passageways each and two inner most rows of 4 passageways each.The 126 glass fiber tows are pulled through the outer two rows of 32 and31 passageways, respectively. The carbon fiber tows are pulled throughthe inner two rows of 4 passageways each. The next bushing splits thetop two rows in half and the left portion is pulled through the leftupper and outer corner passageway in the second bushing. The rightportion is pulled through the right upper and outer corner passageway inthe second bushing. The bottom two rows are split in half and the rightportion is pulled through the lower right outer corner of the secondbushing and the left portion is pulled through the lower left outercorner of the second bushing. Similarly, the two inner rows of carbonare split in half and the fibers of the two right upper passageways arepulled through the inner upper right corner of the second bushing. Thefibers of the left upper passageways are pulled through the inner upperleft corner of the second bushing. The fibers of the right lowerpassageways are pulled through the inner lower right corner of thesecond bushing and the fibers of the left lower passageways are pulledthrough the inner lower left corner of the second bushing.

[0155] The fiber bundles are pulled through a series of seven bushingscontinually compacting and configuring the bundles into one hybridizeduniform concentric core member.

[0156] The composite core member is pulled from the second B-stage oven26 to a next oven processing system 28 at 330° F. to 370° F. wherein thecomposite core member is cured and pulled to a next cooling system 30 at30° F. to 100° F. for cooling. After cooling, the composite core ispulled to a next oven processing system 32 at 330° F. to 370° F. forpost curing. The pulling mechanism pulls the product through a 10 footair cooling area at about 180° F.

[0157] Nine trapezoidal shaped aluminum strands each having an area ofabout 0.0350 sq. in. or about 0.315 sq. in. total area on the core arewrapped around the composite core after cooling. Next, thirteentrapezoidal shaped aluminum strands each strand having an area of about0.0402 sq. in. or about 0.5226 sq. in. total area on the core arewrapped around the inner aluminum layer.

[0158] It is to be understood that the invention is not limited to theexact details of the construction, operation, exact materials, orembodiments shown and described, as modifications and equivalents willbe apparent to one skilled in the art without departing from the scopeof the invention.

We claim:
 1. A composite core for an aluminum conductor composite corereinforced cable comprising: a. a plurality of fibers from at least onefiber type embedded in one or more matrix materials; and b. wherein thecomposite core is a unitary core flexible enough to be wound on atransportation wheel.
 2. A composite core according to claim 1, whereinthe composite core has at least 50% fiber to resin volume fraction, anoperating capability above 100° C., a modulus of elasticity at or above14 Msi, a coefficient of thermal expansion at or above −0.7×10⁻⁶ m/m/°C., and a tensile strength within the range of about 160 Ksi to about380 Ksi.
 3. A composite core according to claim 1, wherein the fibertype is selected one of carbon, Kevlar, basalt, glass, aramid, boron,ceramic, liquid crystal fibers, high performance polyethylene, carbonnanofibers, or carbon nanotubes.
 4. A composite core according to claim1, wherein the matrix material is one of a ceramic, a thermosettingresin, or a thermoplastic resin.
 5. A composite core according to claim1, wherein one or more of the fibers have a 0° orientation.
 6. Acomposite core according to claim 1, wherein two or more of the fibershave two or more orientations.
 7. A composite core according to claim 1,wherein one or more of the fibers are twisted.
 8. A composite coreaccording to claim 1, wherein one or more of the fibers are helicallyplaced around the core.
 9. A composite core according to claim 8,wherein the fibers are placed at an angle to a longitudinal axis of thecomposite core.
 10. A composite core according to claim 1, wherein twoor more of the fibers are interlaced.
 11. A composite core according toclaim 1, wherein two or more of the fibers are braided.
 12. A compositecore according to claim 1, wherein the composite core comprises aconcentric core having an inner layer and at least one outer layer. 13.A composite core according to claim 12, wherein the inner layer is madefrom a first fiber type and at least one outer layer is made from asecond fiber type.
 14. A composite core according to claim 13, whereinthe inner layer is made from a carbon fiber and matrix composite and theouter layer is made from a glass fiber and matrix composite.
 15. Acomposite core according to claim 12, wherein the inner layer is a firsthybridized composite.
 16. A composite core according to claim 12,wherein at least one outer layer is a second hybridized composite.
 17. Acomposite core according to claim 1, wherein the composite corecomprises a first section and at least one other section.
 18. Acomposite core according to claim 17, wherein the first section is madefrom a first fiber type and at least one other section is made from asecond fiber type.
 19. A composite core according to claim 18, whereinthe first section is made from a carbon fiber and matrix composite andat least one other section is made from a glass fiber and matrixcomposite.
 20. A composite core according to claim 17, wherein the firstsection is a first hybridized composite.
 21. A composite core accordingto claim 17, wherein at least one other section is a second hybridizedcomposite.
 22. A composite core for an aluminum conductor composite corereinforced cable comprising: a. a plurality of fibers from at least onefiber type embedded in one or more matrix materials; and b. wherein thefiber type is selected from one of Kevlar, basalt, glass, aramid, boron,liquid crystal fibers, high performance polyethylene.
 23. A compositecore according to claim 22, wherein the composite core is a unitary coreflexible enough to be wound on a transportation wheel.
 24. A compositecore according to claim 22, wherein the composite core has at least 50%fiber to resin volume fraction, an operating capability above 100° C., amodulus of elasticity at or above 14 Msi, a coefficient of thermalexpansion at or above −0.7×10⁻⁶ m/m/° C., and a tensile strength withinthe range of about 160 Ksi to about 380 Ksi.
 25. A composite coreaccording to claim 22, wherein the matrix material is one of a ceramic,a thermosetting resin, or a thermoplastic resin.
 26. A composite coreaccording to claim 22, wherein one or more of the fibers are 0°orientation.
 27. A composite core according to claim 22, wherein two ormore of the fibers have two or more directions.
 28. A composite coreaccording to claim 22, wherein one or more of the fibers are twisted.29. A composite core according to claim 22, wherein one or more of thefibers are helically placed around the core.
 30. A composite coreaccording to claim 29, wherein the fibers are placed at an angle to alongitudinal axis of the composite core.
 31. A composite core accordingto claim 22, wherein two or more of the fibers are interlaced.
 32. Acomposite core according to claim 22, wherein two or more of the fibersare braided.
 33. A composite core according to claim 22, wherein thecomposite core comprises a concentric core having an inner layer and atleast one outer layer.
 34. A composite core according to claim 33,wherein the inner layer is made from a first fiber type and at least oneouter layer is made from a second fiber type.
 35. A composite coreaccording to claim 34, wherein the inner layer is made from a carbonfiber and matrix composite and the outer layer is made from a glassfiber and matrix composite.
 36. A composite core according to claim 33,wherein the inner layer is a first hybridized composite.
 37. A compositecore according to claim 33, wherein at least one outer layer is a secondhybridized composite.
 38. A composite core according to claim 22,wherein the composite core comprises a first section and at least oneother section.
 39. A composite core according to claim 38, wherein thefirst section is made from a first fiber type and at least one othersection is made from a second fiber type.
 40. A composite core accordingto claim 39, wherein the first section is made from a carbon fiber andmatrix composite and at least one other section is made from a glassfiber and matrix composite.
 41. A composite core according to claim 38,wherein the first section is a first hybridized composite.
 42. Acomposite core according to claim 38, wherein at least one other sectionis a second hybridized composite.
 43. A composite core for an aluminumconductor composite core reinforced cable comprising a plurality offibers selected from two or more fiber types embedded in one or morematrix materials.
 44. A composite core according to claim 43, whereinthe composite core is a unitary core flexible enough to be wound on atransportation wheel.
 45. A composite core according to claim 43, thecomposite core having at least 50% fiber to resin volume fraction and anoperating capability above 100° C., a modulus of elasticity at or above14 Msi, a coefficient of thermal expansion at or above −0.7×10⁻⁶ m/m/°C., and a tensile strength within the range of about 160 Ksi to about380 Ksi.
 46. A composite core according to claim 43, wherein the fibertype is one of carbon, Kevlar, basalt, glass, aramid, boron, liquidcrystal fibers, high performance polyethylene, carbon nanofibers, orcarbon nanotubes.
 47. A composite core according to claim 43, whereinthe one or more matrix materials are one of a ceramic, a thermosettingresin, or a thermoplastic resin.
 48. A composite core according to claim43, wherein one or more of the fibers are 0° orientation.
 49. Acomposite core according to claim 43, wherein two or more of the fibershave two or more directions.
 50. A composite core according to claim 43,wherein one or more of the fibers are twisted.
 51. A composite coreaccording to claim 43, wherein one or more of the fibers are helicallyplaced around the core.
 52. A composite core according to claim 51,wherein the fibers are placed at an angle to a longitudinal axis of thecomposite core.
 53. A composite core according to claim 43, wherein twoor more of the fibers are interlaced.
 54. A composite core according toclaim 43, wherein the composite core comprises a concentric core havingan inner layer and at least one outer layer.
 55. A composite coreaccording to claim 54, wherein the inner layer is made from first fibertype and at least one outer layer is made from a second fiber type. 56.A composite core according to claim 55, wherein the inner layer is madefrom a carbon fiber and matrix composite and the outer layer is madefrom a glass fiber and matrix composite.
 57. A composite core accordingto claim 54, wherein the inner layer is a first hybridized composite.58. A composite core according to claim 54, wherein at least one outerlayer is a second hybridized composite.
 59. A composite core accordingto claim 43, wherein the composite core comprises a first section and atleast one other section.
 60. A composite core according to claim 59,wherein the first section is made from first fiber type and at least oneother section is made from a second fiber type.
 61. A composite coreaccording to claim 60, wherein the first section is made from a carbonfiber and matrix composite and at least one other section is made from aglass fiber and matrix composite.
 62. A composite core according toclaim 59, wherein the first section is a first hybridized composite. 63.A composite core according to claim 59, wherein at least one othersection is a second hybridized composite.
 64. A composite core for analuminum conductor composite core reinforced cable comprising: a. afirst layer comprising a first composite; and b. at least one otherlayer comprising a second composite bundled with the first layer.
 65. Acomposite core according to claim 64, wherein the first layer and atleast one other layer are concentric.
 66. A composite core according toclaim 64, wherein the composite core is hybridized.
 67. A composite coreaccording to claim 66, wherein the first layer is made from a firstfiber type and at least one other layer is made from a second fibertype.
 68. A composite core according to claim 67, wherein the firstlayer is made from a carbon fiber and matrix composite and at least oneother layer is made from a glass fiber and matrix composite.
 69. Acomposite core according to claim 66, wherein the first layer is a firsthybridized composite.
 70. A composite core according to claim 66,wherein at least one other layer is a second hybridized composite.
 71. Acomposite core according to claim 64, wherein said composite corecomprises a hybridized concentric core having an inner carbon fiber andmatrix layer and an outer glass fiber and matrix layer.
 72. A compositecore according to claim 64, wherein the first layer is formed with oneof a ceramic, a thermosetting resin, or a thermoplastic resin.
 73. Acomposite core according to claim 64, wherein at least one other layeris formed with one of a ceramic, a thermosetting resin, or athermoplastic resin.
 74. A composite core according to claim 64, whereinthe first composite is a high-strength composite.
 75. A composite coreaccording to claim 64, wherein the second composite is a low-stiffnesscomposite.
 76. A composite core according to claim 64, wherein the firstlayer is a core and the at least one other layer surrounds the firstlayer.
 77. A composite core according to claim 64, wherein the secondcomposite is a low-stiffness composite.
 78. A composite core for analuminum conductor composite core reinforced cable comprising: a. afirst section comprising a first composite; and b. one or more othersections comprising at least one different composite bundled with thefirst section.
 79. A composite core according to claim 78, wherein thefirst composite is formed from a plurality of fibers from a first fibertype embedded in a matrix material.
 80. A composite core according toclaim 79, wherein the first fiber type is carbon.
 81. A composite coreaccording to claim 79, wherein the matrix material is one of a ceramic,thermosetting resin, or a thermoplastic resin.
 82. A composite coreaccording to claim 78, wherein at least one different composite isformed from a plurality of fibers from a different fiber type embeddedin a matrix material.
 83. A composite core according to claim 82,wherein the different fiber type is glass.
 84. A composite coreaccording to claim 82, wherein the matrix material is one of a ceramic,thermosetting resin, or a thermoplastic resin.
 85. A composite coreaccording to claim 78, wherein the first composite is a hybridizedcomposite.
 86. A composite core according to claim 78, wherein at leastone of the different composites is a hybridized composite.
 87. Acomposite core according to claim 78, wherein at least one other sectionforms a lumen.
 88. A composite core according to claim 78, wherein thelumen is filled with a gas or a liquid.
 89. A composite core accordingto claim 78, wherein the gas or liquid is a cooling agent to decreasethe temperature of the cable.
 90. An aluminum conductor composite corereinforced cable, comprising: a. a composite core comprising a pluralityof fibers from at least one fiber type embedded in one or more matrixmaterials; and b. at least one layer of aluminum conductor surroundingthe composite core.
 91. A cable according to claim 90, wherein said atleast one layer of aluminum conductor surrounding the composite corecomprises a plurality of trapezoidal shaped aluminum segments wrappedaround the core.
 92. A cable according to claim 90, wherein a firstlayer of aluminum conductors is helically wrapped around the core.
 93. Acable according to claim 92, wherein a next layer of aluminum conductorsis helically wrapped around the core in an opposite direction from thefirst layer.
 94. An aluminum conductor composite core reinforced cablecomprising: a. a composite core comprising a plurality of fibersselected from two or more fiber types embedded in one or more matrixmaterials; and b. at least one layer of aluminum conductor surroundingthe composite core.
 95. A cable according to claim 94, wherein said atleast one layer of aluminum conductor surrounding the composite corecomprises a plurality of trapezoidal shaped aluminum segments wrappedaround the core.
 96. A cable according to claim 94, wherein a firstlayer of aluminum conductors is helically wrapped around the core.
 97. Acable according to claim 96, wherein a next layer of aluminum conductorsis helically wrapped around the core in an opposite direction from thefirst layer.
 98. An aluminum conductor composite core reinforced cablecomprising: a. a composite core comprising: i. a first layer of ahigh-strength composite; ii. at least one other layer of a low-stiffnesscomposite bundled with the first layer; and b. at least one layer ofaluminum conductor surrounding the composite core.
 99. A cable accordingto claim 98, wherein said at least one layer of aluminum conductorsurrounding the composite core comprises a plurality of trapezoidalshaped aluminum segments wrapped around the core.
 100. A cable accordingto claim 98, wherein a first layer of aluminum conductors is helicallywrapped around the core.
 101. A cable according to claim 100, wherein anext layer of aluminum conductors is helically wrapped around the corein an opposite direction from the first layer.
 102. An aluminumconductor composite core reinforced cable comprising: a. a compositecore comprising: i. a first section of a first composite; ii. at leastone more section of at least one different composite bundled with thefirst section; and b. at least one layer of aluminum conductorsurrounding the composite core.
 103. A cable according to claim 102,wherein said at least one layer of aluminum conductor surrounding thecomposite core comprises a plurality of trapezoidal shaped aluminumsegments wrapped around the core.
 104. A cable according to claim 102,wherein a first layer of aluminum conductors is helically wrapped aroundthe core.
 105. A cable according to claim 104, wherein a next layer ofaluminum conductors is helically wrapped around the core in an oppositedirection from the first layer.
 106. A method of high-speed processing acomposite core comprising the steps of: a. providing a plurality offiber tows; b. guiding the fiber tows through a wet-out system filledwith resin; c. using a B-stage oven and two or more dies spaced apart toshape and compact the fiber tows; and d. curing the composite coremember.
 107. A method according to claim 106, wherein at least one ofthe dies is a plate having a plurality of passageways wherein theorientation of passageways is determined by the desired cross sectionconfiguration of the composite core.
 108. A method according to claim106, wherein at least one of the dies is a bushing.
 109. A methodaccording to claim 106, wherein the wet-out system comprises a system toaid in wetting the fibers.
 110. A method according to claim 106, whereinthe wet-out system is a wet-out tank.
 111. A method according to claim106, wherein shaping and compacting the fiber tows further comprises: a.guiding the fiber tows into a first B-stage temperature oven; b. guidingthe fiber tows into a second B-stage temperature oven comprising aplurality of bushings wherein each bushing comprises a plurality ofpassageways; c. guiding the fiber tows through the bushings and thepassageways; and d. using the bushings to form the composite core. 112.A method according to claim 111, wherein the first B-stage temperatureoven is in the range of about 150° F. to about 350° F.
 113. A methodaccording to claim 111, wherein the second B-stage temperature oven isin the range of about 150° F. to about 350° F.
 114. A method accordingto claim 106, wherein the step of curing the composite core furthercomprises: a. guiding the composite core through a curing oven wherein atemperature of the curing oven is in the range of about 300° F. to about400° F.; b. guiding the composite core through a cooling zone wherein atemperature of the cooling zone is in the range of about 30° F. to about100° F.; c. guiding the composite core through a post-cure oven whereina temperature of the post-cure oven is in the range of about 300° F. toabout 400° F.; and d. guiding the composite core through a cooling zonewherein the core is cooled by air to bring a temperature of the coreinto the range of about 120° F. to about 180° F.
 115. A method accordingto claim 106, wherein the method of processing has a maximum processingspeed above 6 ft/min.
 116. A method according to claim 115, wherein themaximum processing speed is within the range of about 9 ft/min to about60 ft/min.
 117. An electrical power transmission system, having aplurality of cables, wherein at least one cable is an aluminum conductorcomposite core reinforced cable comprising: a. a composite corecomprising a plurality of fibers from at least one fiber type embeddedin one or more matrix materials; and b. at least one layer of aluminumconductor surrounding the composite core.
 118. An electrical powertransmission system according to claim 117, wherein the composite corecomprises: a. a first layer of a first composite; and b. at least oneother layer of a different composite bundled with the first layer. 119.An electrical power transmission system according to claim 117, whereinthe composite core comprises: a. a first section of a first composite;and b. at least one other section of a different composite bundled withthe first section.
 120. A method of constructing an aluminum conductorcomposite core reinforced cable, comprising: a. providing a compositecore comprising a plurality of fibers from at least one fiber typeembedded in at least one matrix material; and b. wrapping at least onelayer of aluminum conductor around the composite core.
 121. An aluminumconductor composite core reinforced cable, comprising: a. a compositecore; b. at least one layer of aluminum conductor surrounding thecomposite core; and c. wherein an ampacity of the cable is 1% to 200%greater than an aluminum conductor steel reinforced (ACSR) cable of asame outside diameter.
 122. A composite core an aluminum conductorcomposite core reinforced cable comprising: a. a plurality of fibersfrom at least one fiber type embedded in one or more matrix materials;b. wherein said fibers for a first portion of fibers and a secondportion of fibers; and c. wherein the first portion of fibers has afirst orientation and the second portion of fibers has a secondorientation, and the first orientation is different from the secondorientation.
 123. A composite core according to claim 122, wherein thefirst portion of fibers is one of unidirectional, multidirectional,interlaced, woven, or braided.
 124. A composite core according to claim122, wherein the second portion of fibers is one of unidirectional,multidirectional, twisted, interlaced, woven, or braided.
 125. Acomposite core according to claim 122, wherein the first orientation isone of 0° orientation or helically placed.
 126. A composite coreaccording to claim 122, wherein the second orientation is one of 0°orientation or helically placed.
 127. A composite core according toclaim 122, wherein the composite core can be wound on a transportationwheel.
 128. A composite core according to claim 122, wherein the firstportion of fibers is a first fiber type and the second portion of fibersis a second fiber type.
 129. A composite core according to claim 122,wherein the first fiber type or the second fiber type is one of carbon,Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, highperformance polyethylene, carbon nanofibers, or carbon nanotubes.
 130. Acomposite core for an aluminum conductor composite core reinforced cablecomprising: a. a first layer comprising a carbon fiber and matrixcomposite; and b. at least one other layer comprising a glass fiber andmatrix composite bundled with the first layer.
 131. A composite coreaccording to claim 130, wherein the first layer has at least 50% fiberto resin volume fraction, a modulus of elasticity within the range ofabout 22 Msi to 37 Msi, a coefficient of thermal expansion within therange of about −0.7×10⁻⁶ m/m/° C. to about 0 m/m/° C., and a tensilestrength within the range of about 160 Ksi to about 370 Ksi.
 132. Acomposite core according to claim 130, wherein the first layer and atleast one other layer are concentric.
 133. A composite core according toclaim 130, wherein the composite core has an operating capability above100° C.
 134. A composite core for an aluminum conductor composite corereinforced cable comprising: a. a first section comprising a carbonfiber and matrix composite; and b. at least one other section comprisinga glass fiber and matrix composite bundled with the first layer.
 135. Acomposite core according to claim 134, wherein the first section has atleast 50% fiber to resin volume fraction, an operating capability above100° C., a modulus of elasticity at or above 14 Msi, a coefficient ofthermal expansion at or above −0.7×10⁻⁶ m/m/° C., and a tensile strengthwithin the range of about 160 Ksi to about 380 Ksi.
 136. A compositecore according to claim 134, wherein the composite core has an operatingtemperature capability above 100° C.
 137. A composite core for analuminum conductor composite core reinforced cable comprising aplurality of fibers selected from a fiber class wherein the compositecore includes two or more fiber types from the fiber class embedded inone or more matrix materials.
 138. A composite core according to claim137, wherein the fiber class is one of carbon, Kevlar, basalt, glass,aramid, boron, liquid crystal fibers, high performance polyethylene,carbon nanofibers, or carbon nanotubes.
 139. A composite core accordingto claim 137, wherein the composite core is a unitary core flexibleenough to be wound on a transportation wheel.
 140. A composite coreaccording to claim 137, the composite core having at least 50% fiber toresin volume fraction and an operating capability above 100° C., amodulus of elasticity at or above 14 Msi, a coefficient of thermalexpansion at or above −0.7×10⁻⁶ m/m/° C., and a tensile strength withinthe range of about 160 Ksi to about 380 Ksi.
 141. A composite coreaccording to claim 137, wherein the one or more matrix materials are oneof a ceramic, a thermosetting resin, or a thermoplastic resin.
 142. Acomposite core according to claim 137, wherein one or more of the fibersare 0° orientation.
 143. A composite core according to claim 137,wherein one or more of the fibers are twisted.
 144. A composite coreaccording to claim 137, wherein one or more of the fibers are helicallyplaced around the core.
 145. A composite core according to claim 144,wherein the fibers are placed at an angle to a longitudinal axis of thecomposite core.
 146. A composite core according to claim 137, whereintwo or more of the fibers are interlaced.
 147. A composite coreaccording to claim 137, wherein the composite core comprises aconcentric core having an inner layer and at least one outer layer. 148.A composite core according to claim 147, wherein the inner layer is madefrom first fiber type and at least one outer layer is made from a secondfiber type.
 149. A composite core according to claim 148, wherein theinner layer is made from a carbon fiber and matrix composite and theouter layer is made from a glass fiber and matrix composite.
 150. Acomposite core according to claim 147, wherein the inner layer is afirst hybridized composite.
 151. A composite core according to claim147, wherein at least one outer layer is a second hybridized composite.152. A composite core according to claim 137, wherein the composite corecomprises a first section and at least one other section.
 153. Acomposite core according to claim 152, wherein the first section is madefrom first fiber type and at least one other section is made from asecond fiber type.
 154. A composite core according to claim 153, whereinthe first section is made from a carbon fiber and matrix composite andat least one other section is made from a glass fiber and matrixcomposite.
 155. A composite core according to claim 152, wherein thefirst section is a first hybridized composite.
 156. A composite coreaccording to claim 152, wherein at least one other section is a secondhybridized composite.